Integrated fill-cap-label system
Complete ATEX Filling Line
Bring container handling, filling, capping, labelling and discharge together as one coordinated line for compatible flammable products.
Machine overview
Keep every hand-off working as one line.
A complete line may include bottle unscrambling, filling, cap feeding, capping, labelling, coding, inspection, conveying and sorting. The real engineering challenge is not only the individual machine—it is the transfer, control and safe operation of the whole process.
The line layout is developed around the site classification, container and closure range, product supply, ventilation, operator access, output and changeover requirements.
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.
Key features
Tailored to your product and production needs.
Protected line modules
Filling, capping and labelling modules are reviewed against the classified area and complete ignition-risk assessment.
Servo volume control
Compatible servo-dosing routes can allow recipe-based volume setting and repeatable changeovers.
Multiple closure styles
Cap feeding and capping can be configured for the actual screw, pump, trigger or specialist closure.
Bottle presentation
Unscramblers, infeed tables and guides stabilise containers before filling.
Line control
Interlocks, emergency stops, accumulation and machine status are coordinated across the line.
Lifecycle support
Installation, commissioning, training, spares and maintenance can be planned with the machinery.
Technical data
Key capabilities to confirm for your project.
| Typical stations | Bottle feed → fill → cap → label → inspect / sort |
|---|---|
| Products | Compatible flammable liquids and pastes after product and hazardous-area assessment |
| Filling | Servo, piston, pump, flow-meter or weigh route according to application |
| Closures | Multiple cap types with manual, assisted or automatic feeding |
| Labelling | Round, front-and-back or other label route according to container |
| Electrical supply | Project-specific; module reference supplies may be 110/220 V |
| Controls | Coordinated line PLC / HMI, interlocks and emergency-stop architecture |
| Safety | Protected components and documentation to the agreed project category and scope |
| Options | Cap feeding, label inspection, coding, accumulation, extraction interfaces and line guarding |
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.
Alcohol products
Bottling lines for compatible alcohol-based products, perfumes and personal-care liquids.
Solvents and fuels
Integrated filling and closure handling for compatible solvents, kerosene and related products.
Viscous flammable products
Creams, coatings or pastes where both product behaviour and hazardous-area controls matter.
Typical supply scope
Support from specification to start-up.
- Configured filler, capper and labeller modules
- Bottle presentation, conveyors and discharge table as specified
- Coordinated controls, guarding and interlocks
- Operating, maintenance and conformity documentation
- Optional FAT, installation, commissioning, training and starter spares
Quote brief
Send these details for a faster, more accurate recommendation.
- Product and container range, with samples or drawings
- Closure and label specifications
- Target sustained output and efficiency assumptions
- Hazardous-area classification across each line section
- Available footprint, access, utilities and extraction
- Coding, inspection, packing and future expansion requirements
Questions
Questions about complete ATEX filling lines.
Does every machine in the line need hazardous-area protection?
The answer depends on the classified zones and how vapour or product can reach each item. The complete line and facility layout must be reviewed, not only the filler.
Can existing cappers or labellers be retained?
Potentially. Existing equipment needs a technical and hazardous-area suitability review, plus an assessment of controls, transfers and line performance.
How is line output calculated?
Sustained output is based on the slowest practical stage after filling time, cap handling, label application, changeovers, operator intervention and accumulation are considered.
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.
☎ 01494 623015✉ sales@lancinguk.comDirect support for new machines, line upgrades and complete filling projects.
Line-level scope
Define the hazardous-area boundary and every machine interface before the line is built.
A complete filling line combines equipment that may have different process functions and different exposure to vapour or product. The filler, capper, labeller and conveyors should not be specified as isolated purchases if the classified area, controls or container transfers connect them.
| Interface | Questions to close |
|---|---|
| Product supply to filler | Source vessel, pump, hoses or pipework, isolation, drainage, recirculation, leak response and cleaning responsibility. |
| Filler to capper | Open-container travel, drip control, vapour release, accumulation, rejects and the location of cap feeding and operator access. |
| Capper to labeller | Closure verification, residual vapour, container cleaning or drying, line speed and whether labelling equipment sits inside the classified boundary. |
| Controls and safety | PLC/HMI ownership, emergency-stop zones, permissives, extraction or earthing interfaces, safe restart, fault recovery and remote signals. |
| Facility services | Power, compressed air, ventilation, extraction, drainage, fire controls, room layout, access and installation verification. |
The line layout should show the classified-area boundary, not only machine footprints.
Include release points, extraction hoods or enclosures, operator positions, doors, access routes, product supply and the equipment that may be affected by vapour migration. The drawing becomes a shared reference for the machinery supplier, site engineer and competent hazardous-area assessor.
Controls, FAT and SAT
Prove the sequence, then verify the installation.
Factory acceptance should demonstrate the agreed line sequence with representative containers, closures and product conditions. Site acceptance then confirms the services and safety interfaces that depend on the installation.
Interlocks
Test no-container/no-fill logic, machine-to-machine permissives, accumulation, rejects, emergency stops and the required response to extraction, guarding or earthing signals included in scope.
Balanced output
Measure sustained output through the complete sequence and identify the real constraint, including cap feeding, labelling, rejects, operator replenishment and changeovers.
Site verification
Confirm final earthing, utilities, airflow or extraction interfaces, equipment locations, access, installation checks, training and the documents handed to the operating team.
Cleaning and changeover should be tested as operating modes, not left as informal procedures. The scope should state which modules contain product, how open containers are cleared, how line sections are isolated and how a safe clean state is confirmed before maintenance or a product change.
What is the difference between line FAT and SAT?
FAT verifies the agreed machine and line functions under stated factory test conditions. SAT verifies installation-dependent matters on site, such as final utilities, extraction, earthing, line position, interfaces with existing equipment and the production conditions that could not be reproduced at the factory.
Can downstream machinery sit outside the hazardous area?
Potentially, if the competent area classification and process design place it outside the boundary and control vapour or product transfer appropriately. The decision must come from the real release sources, ventilation and layout rather than a fixed distance assumed for every project.
Should the line controls be included in the ATEX review?
Yes. Operator devices, control panels, sensors, safety functions, interlocks and any equipment outside the hazardous area that contributes to safe functioning need to be considered within the applicable equipment and machinery scope.
General packaging-line planning outside this domain’s hazardous-area focus is covered by packaginglines.co.uk. For an ATEX project, that wider line design must be reconciled with the declared zones and ignition-control strategy.