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Precise, fast, efficient: Automated filling of containers directly on the pallet
How Fricke ’s semi‐automated filling systems have changed the lubricating oil and grease filling process at PHI OIL
Cleanliness, drip resistance, repeatability and speed are critical factors in the efficient and precise filling of high‐value substances, such as lubricating oil and grease. Austrian company PHI OIL has successfully supplied customers across Europe with a full spectrum of these products since 1998. In order to fill the containers quickly and precisely on the pallet, PHI OIL began using the semi‐automated FFS 21 filling station from Fricke in 2019. This optimized the filling process enormously and proved to be incredibly worthwhile, leading PHI OIL to commission a second station in 2022 to meet rising production quantities.
The company PHI OIL supplies customers across Europe with high‐quality lubricating oils and greases. These are sold in containers of different quantities – from 20‐liter plastic canisters, to 60 and 100‐liter steel barrels, to 1000‐liter Intermediate Bulk Containers (IBC). Cleanliness, drip resistance and repeatability play a critical role in ensuring consistently high product quality during the filling process. While previously, containers were filled with product via a manual process using a scale, the automation of this process means that production orders can now be quickly transferred from the ERP system to the machine control using a barcode scanner. The empty containers are filled with product quickly and precisely, directly on the pallet. “Due to our constantly rising production quantities, in 2019 we decided to take a major step towards automation and convert our filling station to the FFS 21 from Fricke. The new system not only enabled us to perfect our filling process with the corresponding formulation accuracy, but also helped us to fill large quantities of product in a shorter time, allowing us to greatly increase our overall filling quantities,” says Thomas Haunsperger, Managing Director of PHI OIL."
Speed and flexibility in the filling process
With every single filling process, the FFS 21 from Fricke saves time: the ball‐bearingmounted, swiveling telescopic extension allows both radial and linear pivoting movements to overlap, which considerably speeds up the positioning of the filling valve over the container. This shaves valuable seconds of time off each positioning process.
Another advantage of the FFS 21 is the flexible, automated adjustment of the filling process. The software allows various filling programs to be stored in the machine control in advance. For example, if the customer wants to fill an entire pallet with up to three layers of containers, the necessary data such as target and tare weight, coarse and fine flow parameters, and container height can be saved as a program. The container then simply has to be positioned on the pallet and the barcode assigned to the special production order scanned. The system then automatically adapts to the selected filling product and positions the valve at the correct height over the respective container. Other important such as drip trays, fine‐hold contact and upper stop also adjust to the selected production order. This approach avoids time‐consuming filling errors and damage to the machine, as well as dripping of the product due to immersed filling.
Easy and ergonomic handling
The Fricke FFS 21 filling station is leagues ahead of conventional models when it comes to user‐friendliness too. “Radial or coordinate filling systems work with a fixed extension, on which the filling head moves laterally,” explains Dirk Novak, Sales Engineer at Fricke. “As a result, these systems are very inflexible to operate. To adjust to containers that varied in size, such as canisters of intermediate bulk containers, they also need base height adjustment. This set‐up compels the operator to use both hands to control the machine, which leads to greater physical exertion. Our systems, on the other hand, allow one‐handed operation of the filling process, resulting in more ergonomic handling of the machine. In addition, the operator handle can be adjusted to the optimal height for the operator, which significantly reduces strain on the entire back and shoulder area.”
Compact design saves space
The FFS 21 from Fricke provides even more added value with its compact design: “The filling station has a modular structure,” says Dirk Novak. “This allows the customer to choose between different models with one, two or three sets of scales. Depending on the model, the filling station has a minimum footprint of 1.5 x 3 meters and a maximum footprint of 2.5 x 3.5 meters, with a height of 3.3 meters. As a result, it is ideal for use in companies with limited available space.”
This is just one of many advantages that persuaded PHI OIL. “Since 2019, we have optimized our processes enormously by using the two filling stations from Fricke, and are delighted to be able to meet steadily rising demand from our customers even more effectively,” says Thomas Haunsperger.
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FRICKE Abfülltechnik GmbH & Co. KG from Minden, Germany, is a specialist in the development of dosing and filling systems, as well as control software for efficient production processes. Its customers are located around the globe and belong to the perfume and aroma industry, and the chemical industry. At Fricke, broad know-how and over 150 years of experience meet the flexibility and reliability of a family company with more than 115 employees.
About PHI OIL
Since 1998, PHI OIL has specialized in providing highly professional support to corporate customers across Europe, supplying them with a full spectrum of lubricating oils and greases of outstanding quality.
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