The Challenge: Filling a Wide Range of Chemical Products Without Cross-Contamination
A chemical distributor approached us searching for a versatile liquid filling solution capable of handling a wide range of products in both drums and IBC’s. Their product portfolio included chemicals with varying characteristics, including products that are corrosive to stainless steel and require specialized filling components.
Beyond compatibility concerns, the customer needed a solution that would minimize the risk of product cross-contamination while simplifying product changeovers between batches. The ideal system would provide flexibility for filling numerous chemical products while maintaining safe, accurate, and efficient operations.
The Solution
After conducting a site visit & reviewing the customer’s application requirements, HAVER & BOECKER recommended the ELEMENTRA® 16 liquid filler for palletized drums and IBC’s.
Designed for flexibility and precision, the ELEMENTRA® 16 provides chemical distributors with the ability to package a wide variety of liquid products while supporting efficient product changeovers and enhanced operator control.
To meet the customer’s specific requirements, several customized features were integrated into the filling system.
Flexible Filling for Multiple Container Sizes
To accommodate both drums and IBCs, the machine was equipped with Continuous Base Height Adjustment. This feature allows operators to raise and lower the filling arm directly from the HMI with the touch of a button, enabling quick adjustments between different container heights without lengthy setup procedures.
The filling station was also configured with a floor scale and bumper guards, helping protect critical weighing components while ensuring accurate filling performance throughout daily operation.
Simplified Product Control
Because the facility handles numerous products, efficient product selection was a key requirement.
The ELEMENTRA® 16 was equipped with a NAT Router and integrated control interface, enabling operators to communicate directly with the product pump PLC from the machine HMI. This functionality allows operators to select and manage product flow to the filler from a single interface, simplifying day-to-day operation and reducing opportunities for operator error.
Preventing Product Cross-Contamination
One of the most important aspects of the project was preventing the wrong filling components from being used with a product recipe.
To address this challenge, the system incorporates a Valve Encoder identification system that detects which valve and filling lance are connected to the machine. If an incorrect lance or valve is connected for a selected product recipe, the ELEMENTRA® 16 automatically prevents the filling cycle from starting and displays a fault message on the HMI.
This verification process helps protect product quality while reducing the risk of cross-contamination between chemical products.
Faster Product Changeovers
To improve efficiency between production runs, the customer’s system included a Valve Rack and Cleaning Station.
The rack stores spare filling lances while the integrated cleaning station allows operators to clean previously used lances during active production. As a result, operators can install the next filling lance, continue packaging products, and clean the previous lance simultaneously.
This approach significantly reduces changeover time and helps maximize production throughput.
Filling Corrosive Chemical Products
Because some products handled by the customer are corrosive to stainless steel, the filling system was supplied with a Plastic Filling Valve and Lance Kit.
These specialized components provide compatibility with aggressive chemical products while protecting equipment and maintaining long-term reliability. The ability to quickly swap filling lances allows the customer to package both standard and corrosive products on the same machine.
Remote Support Capabilities
To further support uptime, the system was equipped with a Wireless Connection Kit that creates a secure VPN connection for remote access.
This capability enables HAVER & BOECKER service personnel to assist with diagnostics, troubleshooting, and support without requiring an on-site visit, helping reduce downtime and accelerate issue resolution.
Results
The completed project delivered a highly flexible drum and IBC filling system capable of handling a diverse range of chemical products while minimizing the risk of product cross-contamination.
By combining automated recipe verification, rapid product changeovers, compatibility with corrosive chemicals, and remote support capabilities, the ELEMENTRA® 16 provides chemical distributors with a versatile filling solution that can adapt to changing product requirements while maintaining operational efficiency.
For facilities packaging multiple chemical products, the ELEMENTRA® 16 delivers the flexibility, accuracy, and reliability needed to support modern chemical distribution operations.