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Practical ATEX filling advice for your product, packs and production target

Jerrycan, pail and drum filling

ATEX Bucket & Drum Filling Machine

Fill heavier containers with better control of weight, splash, foam, operator access and safe movement of the finished pack.

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Semi-automatic bucket and jerrycan filling machine with scale and roller conveyor

Machine overview

A practical solution for heavier finished packs.

Five to thirty litre containers create different handling and ergonomic questions from small bottles. Weighing, diving nozzles, feed pumps and roller or powered conveyors can be combined to control filling and move the heavier finished container safely to capping or discharge.

Where the product or environment is hazardous, the filler and every related component are reviewed against the declared classification. Large-pack projects also need early decisions about manual handling, cap application, pallet preparation and cleaning access.

Hazardous-area suitability is project-specific.

The final machine category, marking, electrical and non-electrical equipment, controls, documentation and installation requirements must match the competent site assessment and agreed specification.

Semi-automatic bucket and jerrycan filling machine with scale and roller conveyor

Key features

Tailored to your product and production needs.

1

Weigh-by-fill control

An integrated scale can stop the fill at the target mass and support repeatable large-volume dosing.

2

Diving nozzles

Nozzles can follow the rising liquid level to reduce splash and foam for suitable products.

3

Product feed pump

A compatible pump maintains supply to the filling head and is selected around viscosity and hazard.

4

5–30 litre range

A practical reference platform for pails, jerrycans, cans and small drums.

5

Container transfer

Roller or powered conveyors are planned around filled weight, stability and operator workflow.

6

Capping integration

Manual, assisted or automatic closure handling can be considered in the same layout.

Technical data

Key capabilities to confirm for your project.

Platform referenceLUGTW2S family / configured hazardous-area variant
Reference fill range5–30 L
Reference outputApproximately 100–120 containers/hour, volume and product dependent
Reference accuracy±0.5% on suitable weigh-fill applications
NozzlesOne or two diving heads, project dependent
Product supplyCompatible gear pump or alternative feed system
Maximum weighingUp to 50 kg on reference platform
Air supplyApproximately 0.5–0.7 MPa reference
Electrical supplyProject-specific; reference non-ATEX platform data may use 380 V, 50 Hz
ConveyingRoller or powered conveyor, length and height to layout
OptionsCap application, fume interface, drip tray, grounding, pallet handling and integrated line controls

Indicative platform data only. Final performance, conformity, utilities and dimensions are confirmed against the product, container, hazardous-area classification and approved project specification.

Applications

Typical applications.

I

Industrial solvents

Larger packs of compatible flammable solvents and cleaners.

P

Paints and coatings

Pails and cans where viscosity, splash and lid handling affect the line.

O

Oils and additives

Lubricants, kerosene and compatible products requiring robust large-pack handling.

Typical supply scope

Support from specification to start-up.

  • Configured weigh filling station
  • Scale, nozzle and product-feed arrangement
  • Roller or powered conveyor sections as specified
  • Protected controls and static provisions to agreed scope
  • Documentation, training and optional commissioning

Quote brief

Send these details for a faster, more accurate recommendation.

  • Jerrycan, bucket or drum drawings and filled weight
  • Product SDS, density, viscosity, foam and compatibility
  • Hazardous-area classification and extraction details
  • Target output and operator involvement
  • Closure type, torque or lid-press requirement
  • Downstream conveying, labelling and pallet workflow

Questions

Questions about bucket and drum filling.

Can the same machine fill 5 litre and 30 litre containers?

A wide range may be possible, but nozzle travel, scale capacity, container geometry, change parts, fill time and operator workflow must be reviewed.

Can capping be included?

Yes. Screw capping, lid pressing or operator-assisted closure stages can be integrated, subject to the closure, container and hazardous-area requirements.

How are foamy products handled?

Diving or bottom-up nozzles, controlled fill profiles and suitable cut-off can help, but the product should be assessed or trialled at the required dose and speed.

Your machine recommendation

Tell us what you need to fill — we’ll recommend the most suitable machine.

Send your product SDS, container details, fill range, target output and any ATEX information. You’ll receive a practical shortlist matched to your application.

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Large-pack engineering

Treat container handling, nozzle travel and product supply as part of the fill.

The LUGTW2S reference family covers a configured 5–30 litre route, but the practical machine is defined by the pack geometry, filled weight, neck position, product flow and the operator or conveyor sequence. A stable fill is only useful when the finished container can be closed and moved without creating a spill or manual-handling problem.

Container presentation and ergonomics

Record the base, handle, neck offset and centre of gravity of every bucket, pail or jerrycan. The scale, guides and nozzle need to locate the pack repeatably. For manual loading, agree the lift, reach and finished-pack movement; for conveyor loading, agree the roller pitch, drive, stops and how the scale is isolated during measurement.

The proposed closure stage should be included from the beginning. A screw cap, plug, lid or bung can change the container support, operator access and the point at which vapour or product remains exposed.

Product feed and nozzle control

Large doses place greater demand on the feed pump, hose and valve. Specify viscosity and density at operating temperature, supply pressure, source vessel, batch level variation and whether recirculation is required. The fill profile may use coarse and fine stages to balance output and cut-off.

Diving nozzles can reduce splash or foam for suitable products, but the travel, nozzle diameter, material, bottom clearance and withdrawal speed require confirmation with the real pack. A drip tray or local containment should be sized around the credible release and cleaning method, not used as a substitute for process control.

Plastic packs do not become safely earthed by attaching an arbitrary clamp.

Static-control measures depend on the product, conductivity, container material, fill method and wider transfer system. The competent risk assessment should define the control strategy, while the machine specification identifies the monitoring, interlocks and connection points included in the supply.

Trial and FAT

Test the pack-handling sequence as well as fill accuracy.

Test stageWhat to observe
Empty-pack loadingStable positioning, tare method, handle clearance and correct detection of missing or misaligned packs.
Nozzle entryNeck clearance, bottom position, splash, foam and contact avoidance across the complete container range.
Cut-offCoarse/fine response, residual flow, drips and result against the agreed measurement method.
Closure and transferSafe access, cap or lid handling, container stability and movement of the finished weight.
Cleaning and recoveryDrainability, retained product, flush route, drip-tray access and waste or product-recovery arrangements.
Does the published 5–30 litre range cover every bucket or jerrycan?

No. It is a reference fill range. The container height, base, neck position, stability, handle, nozzle travel, scale capacity and finished-pack handling must all fit the configured station.

Can large plastic containers be filled with an earthing clamp?

An earthing clamp is not automatically effective on an insulating plastic container. Static control needs to consider the product, container, operator, product supply and surrounding equipment. The solution may involve several measures defined by the competent assessment rather than a single accessory.

What FAT evidence is most useful for a bucket or drum filler?

Use real containers and closures, the agreed product or representative medium, a stated run length, mass or volume measurement records, output timing, nozzle and drip observations, alarm/interlock checks, operator-handling observations and a list of site checks reserved for SAT.

Use the trial and FAT planning guide

ATEX drum-filling scope

Define the actual container before treating “drum filling” as one machine category.

The published LUGTW2S reference route on this page covers configured 5–30 litre containers and a maximum weighing reference of up to 50 kg. It can include buckets, pails, jerrycans, cans and smaller drums. A 200 litre drum, an IBC or a palletised multi-drum operation is a materially different handling and engineering project and should not be inferred from the reference platform.

Container detailWhy it changes the fillerInformation to send
Open-head pail or bucketWide openings can support lance or diving-nozzle access, but foam, splash, lid handling and exposed-product time need control.Opening diameter, height range, handle position, lid type, filled weight and required closure method.
Tight-head jerrycan or small drumOffset necks and narrow openings affect guides, nozzle diameter, venting, lance travel and repeatable positioning.Base and neck drawings, cap or bung, vent arrangement, material, conductivity information where relevant and pack tolerances.
Metal versus plastic packConductive metal and insulating plastic cannot be treated through the same generic earthing assumption.Material specification, product conductivity data where available, transfer method and the competent static-control strategy.
Manual versus conveyor transferManual loading affects lift, reach and operator exposure; conveyor transfer affects scale isolation, stops, roller pitch and accumulation.Hourly target, filled weight, operator tasks, infeed/outfeed height, downstream closure and pallet workflow.

Open-container time matters

For volatile or flammable products, record the period from nozzle entry to closure and every place a filled open pack may wait. The extraction or containment review should include normal transfer, a blocked cap station, rejected packs and the method used to clear the line after a stop.

A diving nozzle can help with splash or foam for a suitable product, but it does not by itself define vapour control. Bottom clearance, withdrawal speed, nozzle wetting, retained drips and the pack’s venting behaviour should be observed with representative samples.

Handling evidence belongs in FAT

A useful test includes empty-pack loading, tare or zero stability, nozzle entry, coarse/fine cut-off, cap or lid access and movement of the finished weight. Operator reach and the action needed after a misaligned pack should be treated as acceptance issues rather than left until installation.

Use the earthing and bonding guide for the conductive path and monitoring brief, and the trial and FAT guide for a recorded test matrix.

Ask for a separate engineered proposal when the pack is outside the published reference route.

Send the real drum or IBC drawing, capacity, filled weight, pallet arrangement, opening, closure, output and handling sequence. Lancing can then confirm whether a different weigh platform, lance arrangement, conveyor, pallet system or project partner is required rather than applying unsupported figures from a smaller machine.

Large-pack project plan

Design the fill station around full-container weight, movement and operator access.

For pails, jerrycans and drums, the handling task can dominate the cycle. The project should define how empty packs arrive, how they are located and bonded where applicable, how the nozzle enters, and how the filled pack moves to closure or discharge without uncontrolled lifting or contact with the weighing system.

Handling stageQuestions to resolveRelated guide
Empty-pack infeedManual placement, rollers, pallet handling, orientation and access.Installation and layout
Quantity controlMass target, tare, coarse/fine flow, nozzle force and stable cut-off.Load-cell vs volumetric
Vapour and dripsNozzle travel, open-pack period, local capture, cut-off and spill route.Extraction and containment
LifecycleHoses, clamps, rollers, load cells, product connections and inspection access.Maintenance and inspection

Large-container questions

Questions buyers ask about pail, jerrycan and drum filling layouts.

The filled pack can be the dominant mechanical and operational constraint. Define how it is supported, filled, closed and removed before choosing the station arrangement.

How should full-container weight change the layout of a drum filling station?

Full-container weight should determine the support surface, transfer method, operator reach, accumulation limit and recovery plan for the station. A pack that is easy to present empty may be unsafe or impractical to rotate, lift or reposition after filling.

Provide the empty and maximum filled mass, base dimensions, handle or lifting points, pallet pattern and intended movement method. The layout should show how a rejected, leaking or partially filled container is isolated without requiring an improvised manual lift.

When are top filling, subsurface filling or lance travel reviewed?

The nozzle path is reviewed when splash, foam, vapour release, static, container depth or fill-surface behaviour makes a fixed top-fill position inadequate. A diving or travelling lance may help a defined product and pack, but its insertion depth, withdrawal profile, cleanability, collision risk and drip control must be tested.

The choice is not a universal ATEX rule. It follows the product behaviour, container opening, hazardous-area assessment and the way the open pack is contained and transferred.

How should open pails or drums move to closure?

Open pails or drums should move to closure through a defined route that controls stability, drips, exposed product and the time the container remains open. The line layout must account for the closure supply, operator access, lid placement or capping force and any hazardous-area boundary crossed during transfer.

State whether closure is immediate, manual, semi-automatic or integrated; where spills are contained; and what happens if the closure station is unavailable. A downstream blockage should not create an uncontrolled queue of open containers.

What pack-handling data is needed for pallet, roller or conveyor transfer?

Pack-handling design needs the container footprint, base stiffness, centre of gravity, maximum mass, surface condition, pallet use, orientation, allowable contact points and required accumulation. Handles, tapered walls, damaged bases and flexible plastic can alter how a nominally similar pack behaves on rollers or guides.

Send representative empty containers and, where practical, simulate the filled mass during handling trials. The plastic-container guide also explains why material and static behaviour cannot be inferred from dimensions alone.

Define the pack journey before the station footprint.

Use the nozzle selection questions together with the existing site-preparation guide to connect filling, handling and closure.

Beyond the published 5–30 litre reference range

Planning 200 litre drums or IBCs requires a separate large-container filling scope.

The scale, nozzle arm, pallet handling, product-transfer rate, vapour displacement and overfill consequences are materially different from the reference bucket and jerrycan platform. Use the dedicated ATEX IBC and 200 litre drum filling guide before treating a larger pack as a simple range extension.

Large-pack project framework

Container, pallet, measurement, top or bottom fill, extraction, earthing, closure and material movement.

Flowmeter or load cell?

Define the accepted quantity and test conditions before selecting the measuring instrument.

Large-pack protection

Define the normal endpoint, nozzle travel and abnormal overfill response together.

Need a filling system that fits your product, packs and output?

Share your SDS, hazardous-area information, containers, fill volumes, target output and any capping or labelling stages.

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