Production Case: ZS-AFC44 Testing for 35ml and 60ml Airless Pump Bottles
Airless pump bottles are widely used for cosmetic creams, lotions, serums, gels, and other viscous products. For manufacturers, stable filling and accurate assembly are important because the packaging consists of several components, including the bottle, internal piston, pump head, and outer cap.
In this production case, a customer sent two sizes of airless pump bottles for machine evaluation. Both bottles had the same diameter but different heights and filling capacities:
- 35ml airless pump bottle
- 60ml airless pump bottle — same diameter, different height and filling volume
The bottles were tested on the ZS-AFC44 Automatic Airless Pump Bottle Filling and Capping Machine. Our engineers adjusted the machine according to the actual bottle structure and completed the trial process from bottle positioning to filling and cap assembly.
1. Project Overview
The purpose of this project was to evaluate the compatibility of the ZS-AFC44 with two airless pump bottle sizes supplied by the customer. Both bottles shared the same diameter, which allowed them to use the same basic bottle handling system. However, their different heights and capacities required adjustment of the working positions and filling settings.
| Item | Requirement |
|---|---|
| Machine Model | ZS-AFC44 |
| Packaging Type | Airless Pump Bottles |
| Bottle Sizes | 35ml and 60ml |
| Bottle Diameter | Same |
| Bottle Height | Different |
| Filling Volume | 35ml / 60ml |
| Application | Cosmetic cream and other suitable paste or liquid products |
2. Bottle & Packaging Requirements
An airless pump bottle is not simply a bottle and a cap. The complete packaging structure includes multiple components that must be assembled in the correct sequence. For this project, the packaging components were evaluated individually before the trial:
- Empty airless bottle
- Internal piston or base component
- Product
- Pump head or upper assembly component
- Outer cap
Height difference consideration
Because the two bottles had different heights, the engineer needed to check the relative position of each component during machine operation. The same diameter simplified some changeover requirements, but the height difference meant working positions could not simply remain unchanged when switching between the 35ml and 60ml bottles.
Before production testing, the engineering team checked the bottle structure, component dimensions, and assembly relationship to determine which machine stations required adjustment.
3. Machine Configuration & Workflow
The ZS-AFC44 is designed for the filling and assembly of airless pump bottle packaging. For this project, the production workflow was arranged around the customer's actual packaging structure.
Base Pressing Station
The airless bottle base or internal component is positioned and pressed into place according to the bottle structure. This stage is important because the component must be correctly installed before subsequent filling and assembly operations.
Filling Station
The product is filled into the bottle according to the required volume. For this project, the filling volume needed to be adjusted when switching between the 35ml bottle and the 60ml bottle.
Cap Placement Station
The pump head or upper cap component is supplied and positioned onto the filled bottle. The positioning needs to match the actual dimensions and structure of the customer's packaging component.
Cap Pressing Station
After placement, the cap pressing mechanism presses the component into the required position. The pressing position and pressure need to be checked during the trial to ensure stable assembly without damaging the packaging.
Finished Product Output
After completing the required assembly operations, the finished bottles move to the output section for inspection. The exact automation level can also be configured according to the customer's production requirements.
4. Factory Setup & Trial
The factory trial was carried out using the customer's two actual bottle samples. Because the bottles had the same diameter but different heights, the engineering team focused on adjusting the vertical working positions and filling parameters.
Step 1: Base Pressing Adjustment
The working position was adjusted according to the actual height and structure of the customer's airless bottles. The engineer checked bottle positioning, vertical working height, alignment between the pressing mechanism and the bottle component, and the assembly condition after pressing.
Step 2: Filling Station Adjustment
Since the project involved both 35ml and 60ml bottles, the filling settings needed to correspond to the selected bottle size. The engineer adjusted and checked filling nozzle position, bottle-to-nozzle alignment, filling height, filling parameters, and filling volume.
Step 3: Cap Placement Adjustment
The engineer adjusted the working position according to the dimensions of the actual packaging component. The trial focused on component feeding position, cap or pump head orientation, positioning accuracy, and alignment with the bottle opening. Each adjustment was checked through actual assembly testing.
Step 4: Cap Pressing Adjustment
Because the two bottle sizes had different heights, the vertical position needed to be considered when changing between sizes. The engineer checked pressing position, bottle support during pressing, alignment between the pressing mechanism and the cap component, and finished assembly appearance. Adjustments were made step by step to avoid excessive pressure or incorrect positioning.
Step 5: Volume Calibration
The machine was configured for both 35ml and 60ml capacities. After setting the target filling parameters, sample bottles were filled and inspected. The calibration process includes repeated sampling and measurement until the actual filling result matches the required production setting.
For a production project, the final filling setting should always be confirmed using the customer's actual product and packaging, as material characteristics such as viscosity and flow behavior can affect filling performance.
5. Trial Results
After the main stations were adjusted, the machine was tested using the customer's actual airless pump bottle samples. The factory trial focused on the following checkpoints:
- Whether the bottle could be positioned correctly
- Whether the base component could be pressed into place
- Whether the filling process matched the selected bottle size
- Whether the filling volume could be set and calibrated
- Whether the pump head or cap component could be positioned correctly
- Whether the cap pressing process produced a proper assembly result
- Whether the finished bottle appearance was acceptable
For the two bottle sizes in this project, the key difference was bottle height and filling capacity. Since the diameter remained the same, the trial mainly involved adjusting the relevant vertical working positions and filling settings when changing between the 35ml and 60ml bottles.
6. Project Summary
This project demonstrates how the ZS-AFC44 can be evaluated using a customer's actual airless pump bottle packaging. The customer provided a 35ml bottle and a 60ml bottle. Although the two bottles had the same diameter, their different heights and capacities required the machine to be adjusted accordingly.
Using actual customer samples allows the engineering team to evaluate the compatibility of the bottle and packaging components before finalizing the production configuration.
Evaluate the ZS-AFC44 for Your Airless Pump Bottle Project
If you are planning to fill and assemble airless pump bottles, providing the following information can help us evaluate your application:
- Bottle photos, dimensions, diameter and height
- Bottle capacity
- Pump head and cap photos and packaging component details
- Product photo or video and viscosity characteristics
- Required production capacity
For custom bottle designs or multiple packaging sizes, you can also send physical samples to our factory for machine evaluation and trial testing. Contact ZONESUN with your bottle and product information for further machine evaluation.