What are the differences in filling accuracy between different models of gran...
Differences in filling accuracy between different models
Differences in quantitative methods lead to different accuracy: Common quantitative methods of granular tea bag filling and packaging machines are volumetric quantitative and weighing quantitative. For volumetric quantitative packaging machines, different models have differences in the design and manufacturing accuracy of the filling chamber. The filling chamber processing accuracy of some basic models is limited, which may cause the volume deviation of each granular tea to be ±2-5 ml. For granular tea with relatively stable density, the weight deviation is about ±1-3 grams. The high-end models can control the volume deviation to ±1-2 ml and the weight deviation to ±0.5-1 gram through more precise machining and optimized chamber structure design. For weighing quantitative packaging machines, economical products may use ordinary weighing sensors with an accuracy of ±0.5-1 grams, while mid-to-high-end models are equipped with high-precision weighing sensors, which can improve the accuracy to ±0.1-0.3 grams, with obvious advantages in filling accuracy.
The degree of automation affects the stability of accuracy: For packaging machines with a low degree of automation, there is more manual intervention in the transportation and filling of granular tea leaves. The different techniques and proficiency of different operators will cause large fluctuations in filling accuracy. For example, it is difficult to ensure the same amount of material each time by manually controlling the feeding speed of granular tea leaves, resulting in a filling accuracy deviation of up to ±3-5 grams. The fully automated packaging machine can accurately control each action through the program, reduce human interference, and maintain a relatively stable filling accuracy. Some intelligent packaging machines use advanced PLC control systems to control the accuracy fluctuation within a very small range, and the deviation is generally within ±0.5 grams.
The brand technology accumulation causes the accuracy gap: Brands that have been deeply involved in the packaging machine field for many years and have mature technology often perform better in terms of filling accuracy. After long-term research and development and practice, such brands have continuously optimized the mechanical structure and electronic control system of the equipment. For example, a certain model of packaging machine of a well-known brand can achieve extremely high filling accuracy with a deviation of about ±0.2 grams by virtue of its unique material conveying system and precise metering device. However, due to insufficient technical accumulation, some emerging brands or small brands may have a large room for improvement in filling accuracy, and the deviation may reach ±1-2 grams.
Key factors affecting filling accuracy
Material characteristics: The uneven shape, size, and density of granular tea will affect the filling accuracy. Particles with irregular shapes and large size differences are prone to jamming and blockage during transportation and filling, resulting in unsmooth material feeding and unstable filling volume. For example, some granular tea with more broken pieces are mixed with complete particles. When volumetric quantitative measurement is performed, the broken pieces may fill the gaps between large particles, affecting the actual filling volume. Granular tea with inconsistent density will have a large difference in weight even if the volume is the same, and it is difficult to ensure accuracy when weighing quantitative measurement.
Wear of mechanical parts of equipment: The key mechanical parts of the packaging machine, such as the conveying screw, filling valve, metering chamber, etc., will wear out after long-term use. The wear of the conveying screw will change its pitch, resulting in inaccurate material conveying volume; the wear of the filling valve may cause loose sealing, material leakage or dripping, affecting the filling volume; the wear of the metering chamber will change its volume, directly leading to a decrease in filling accuracy. Generally speaking, after the mechanical parts have been running for 5000-8000 hours, if they are not maintained or replaced in time, the filling accuracy deviation will gradually increase, which may increase from the initial ±0.5 grams to ±1-2 grams.
Stability of electronic control system: The electronic control system is responsible for controlling the operating speed, time and other parameters of each component of the equipment. If the system is unstable, such as sensor failure, controller program error, etc., the action of the packaging machine will be out of adjustment, which will affect the filling accuracy. For example, zero drift of the weighing sensor will lead to inaccurate weighing and excessive filling volume deviation; jamming or erroneous instructions in the controller program during operation may cause the material conveying time to be too long or too short, resulting in abnormal filling volume.
Environmental factors: The temperature and humidity of the working environment have an impact on both granular tea leaves and equipment. In a high temperature environment, granular tea leaves may dry out due to evaporation of water, resulting in changes in density, affecting the accuracy of weighing and volume measurement. When the humidity is high, granular tea leaves are prone to moisture absorption and sticking together, affecting the smoothness of material feeding. At the same time, if dust and impurities in the environment enter the interior of the equipment, it may affect the normal operation of mechanical parts and have an adverse effect on filling accuracy. For example, in an environment with a relative humidity of more than 70%, after the granular tea leaves absorb moisture, the filling accuracy deviation may increase by ±0.5 - 1 gram.