Filling Machine Failures: Top 7 Causes and How to Fix Them

1. Low/No Air Pressure Failure

Symptoms: Machine halts, pneumatic components unresponsive.
Solution:

• Open air supply valves fully

• Check compressor pressure (adjust to 6-8 bar)

• Inspect for leaks in air lines
  Prevention:

Daily: Verify pressure gauges before startup
Weekly: Clean air filters & check regulator function

2. Start/Stop Button Failures

Symptoms: Unresponsive controls, intermittent operation.
Solution:

• Replace faulty push buttons

• Test wiring continuity (multimeter required)

• Reset emergency stop switches
  Prevention:

Train operators on proper shutdown sequences
Monthly button sensitivity checks

3. Motor Overload Shutdowns

Symptoms: Sudden stops, overheating warnings.
Solution:

• Allow motors to cool (15-20 mins)

• Replace blown overload relays

• Check contactors for arcing damage
  Critical Step:

Always measure current draw before restarting!

4. PLC & Power Supply Failures

Symptoms: Blank control screen, unlit indicators.
Solution:

• Verify 24V DC power supply output

• Inspect PLC status LEDs (error codes?)

• Replace damaged I/O modules
  Prevention:

Install voltage stabilizers
Quarterly PLC backup battery replacement

5. Electrical Phase Loss

Symptoms: Uneven operation, humming transformers.
Solution:

• Test all 3 phases at main breaker

• Replace faulty circuit breakers

• Check transformer input/output voltages
  Warning:

Never bypass phase monitors – risk of motor burnout!

6. Output Component Failures

Symptoms: Valves not triggering, inconsistent fills.
Solution:

• Swap faulty relays (listen for clicks)

• Test solenoid coils (should show 5-20Ω resistance)

• Replace stuck air valves
  Pro Tip:

Keep spare relays/coils in maintenance kits

7. Sensor & Valve Malfunctions

Symptoms: Incorrect fill levels, leakage.
Solution:

• Clean optical sensors with alcohol wipes

• Rebuild sticking valves (replace seals)

• Calibrate level detectors
  Prevention:

Seal electrical enclosures against moisture
Monthly pneumatic valve lubrication

Maintenance Checklist to Avoid Downtime

Recommended by Packaging Engineers

Decision matrix for maintenance teams:

“Filling Machine failures are 90% caused by avoidable electrical or pneumatic issues. Regular maintenance always outperforms last-minute repairs.”
– Packaging Line Supervisor, Beverage Plant