Tube Filling, Crimping & Batch Coding Machine

Engineered Excellence for High-Yield Tube Packaging Lines

In the modern manufacturing landscape, line efficiency, volumetric accuracy, and absolute hygiene dictate market success. The Harsiddh Tube Filling, Crimping & Batch Coding Machine is an advanced, fully integrated solution engineered to automate the complete packaging lifecycle of collapsible tubes. Combining multi-station rotary mechanics with precise dosing technology, this high-performance system delivers an unbroken “fill-to-finish” workflow on a singular, space-optimized industrial platform.

Designed explicitly to handle the complex rheological challenges of highly viscous and semi-viscous formulations, this versatile system bridges the gap between raw product processing and shelf-ready retail presentation. Whether your line demands the hermetic mechanical folding of structural aluminum or the dynamic thermal sealing of multilayer co-extruded laminate tubes, the Harsiddh system adapts rapidly, protecting your product integrity and accelerating your time-to-market.

Technical Versatility Across Key Industrial Sectors

Every industry carries its own regulatory pressures, compliance thresholds, and material characteristics. The Harsiddh rotary tube processing system is structurally and operationally optimized to meet the strict production standards across multiple industrial fields:

1. Pharmaceutical & Biotech

Built in accordance with strict cGMP regulations, this machine is ideal for packing medicated ointments, sterile creams, topical gels, and transdermal pastes. Standardizing contact surfaces with sanitary-grade stainless steel ensures zero cross-contamination and compatibility with aggressive chemical formulations.

2. Cosmetics & Personal Care

The personal care industry relies on aesthetic perfection and structural consistency. The machine flawlessly doses high-viscosity products like toothpastes, skincare lotions, mud masks, hair colorants, and shaving gels into retail-ready packaging without causing product aeration or external tube smudging.

3. Industrial Chemicals & Adhesives

Handling dense, high-tack formulations requires robust mechanical torque and clean cut-offs. The system handles challenging compounds—including silicones, structural adhesives, resins, greases, and rubber cements—with customized nozzle configurations that eliminate stringing or weeping.

4. Food & Nutraceuticals

For applications packaging food pastes, spreads, purées, and icing gels, the system preserves raw ingredient integrity under strict sanitary conditions. Specialized cleaning options and non-toxic sealing elements prevent contamination, keeping food products fresh and shelf-stable.

Dual-Material Capability: Aluminum, Plastic, and LAMI Tubes

Production lines must remain agile as consumer trends and material costs fluctuate. The machine features a highly adaptable architecture capable of processing different tube materials with minimal conversion overhead:

• Aluminium Tubes (Mechanical Crimping): When processing traditional aluminum packaging, the machine deploys a series of precise mechanical folding rollers and flattening jaws. This forms a tight double, triple, or saddle-fold crimp, establishing a secure barrier against leakage without compromising the metal’s structure.
• Plastic & LAMI Tubes (Thermal Sealing): By switching to a specialized hot-air or heated-jaw sealing assembly, the machine handles co-extruded plastic and complex laminated (LAMI) materials. High-frequency thermal application melts the inner polymer linings uniformly, while water-cooled code jaws clamp down to create a clean, uniform cosmetic seal.

Detailed Breakdown: The High-Efficiency 8-Station Rotary Process

The core of the machine’s high-throughput performance lies in its continuous, synchronized 8-pocket rotary indexing disc. As empty tubes move smoothly through each station, specialized mechanical and electronic systems perform dedicated preparation, filling, closure, and inspection steps with surgical precision.

+-------------------------------------------------------------+
|                8-STATION ROTARY WORKFLOW                    |
+-------------------------------------------------------------+
|  [Station 1 & 2]  -->  Tube Feeding & Automated Loading     |
|  [Station 3]      -->  High-Pressure Internal Vacuum Clean  |
|  [Station 4]      -->  Smart Sensing ("No Tube - No Fill")  |
|  [Station 5]      -->  Precision Positive Displacement Fill |
|  [Station 6]      -->  Material-Specific Crimping & Sealing |
|  [Station 7]      -->  Batch Coding & Alphanumeric Embossing|
|  [Station 8]      -->  Automatic Ejection to Secondary Line |
+-------------------------------------------------------------+

Stations 1 & 2: Automated Tube Feeding & Orientation

Empty tubes are fed systematically into precision-bored, material-safe holders mounted on the main rotary disc. This dual-station mechanism manages the initial loading and stabilizes the tubes horizontally and vertically, aligning them perfectly for downstream operations.

Station 3: Deep-Clean Vacuum Sanitization

Before introducing the product, an automated, high-pressure vacuum nozzle drops directly into the tube cavity. A targeted blast of clean air breaks up static bonds, lifting any micro-dust particles, cardboard lint, or packing residues. The synchronized vacuum instantly extracts these impurities, maintaining strict internal hygiene.

Station 4: Smart Sensing & Anti-Wastage Validation

Equipped with an advanced electro-mechanical or optical sensor array, this station verifies the presence and correct orientation of the tube. If a pocket is empty or a tube is deformed, the system sends an immediate bypass signal to the next station. This “No Tube – No Filling” safety logic protects your facility floor from messy spills and saves valuable raw materials.

Station 5: Precision Volumetric Dosing

Once validation is successful, a positive-displacement piston pump dispenses an exact volume of product into the tube. The filling nozzle features an optimized bottom-up lifting stroke and a positive shut-off mechanism. This design prevents air pockets within the product and cuts off cleanly, keeping the tube rim residue-free for a perfect seal.

Station 6: Material-Specific Crimping and Sealing

At this station, the tube is hermetically sealed based on its material composition:

• Metal Tubes: Mechanical folding jaws execute sequential folds to create a neat, pressure-resistant seam.
• Synthetic/Composite Tubes: Thermally regulated sealing elements melt the material at the precise sealing zone before cooling jaws compress it into a clean, smooth finish.

Station 7: Integrated Alphanumeric Batch Coding

Traceability is critical for modern regulatory compliance. This station uses heavy-duty mechanical embossing dies to stamp permanent character strings directly onto the flattened tube seal. This lets you apply clear lot numbers, manufacturing (MFG) dates, and expiration markers that remain legible throughout the product’s shelf life.

Station 8: Automated Ejection & Line Integration

The fully enclosed, filled, and coded tube reaches the final station, where a mechanical lifter gently pushes it up from the holder. A synchronized discharge arm shifts the finished tube onto an exit chute or a motorized takeaway conveyor, directing it smoothly toward secondary cartoning, bundling, or case-packing lines.

Strategic Operational & Safety Features

• Robust Monoblock Chassis: Built on a heavy-duty stainless steel structural frame, the machine minimizes vibration during high-speed indexing, extending component lifespans and ensuring consistent dosing.
• Ergonomic Operator Interface (HMI): A centralized, intuitive control panel provides real-time access to production counts, cycle speeds, sealing temperatures, and diagnostic fault alerts.
• Rapid Tool-Less Changeovers: Designed with modular change parts, your line operators can transition between different tube sizes, diameters, and formulations with minimal downtime.
• Comprehensive Safety Enclosures: Interlocked acrylic or polycarbonate guards surround the moving rotary disc, protecting operators from moving parts while maintaining visibility during production.

Technical Specifications

Feature	Model: ATFM-S (Single Head)	Model: ATFM-D (Double Head)
Production Output	Up to 30 tubes/minute	Up to 50 tubes/minute
Filling Stations	Eight	Eight
Fill Volume Range	5ml to 100ml	5ml to 50ml
Tube Diameter	12mm to 25mm	12mm to 25mm
Tube Length	50mm to 200mm	50mm to 200mm
Power Consumption	1.5 H.P.	3.0 H.P.
Electricals	440V, 3 Phase, 50Hz	440V, 3 Phase, 50Hz
Net Weight	Approx. 350 Kg	Approx. 450 Kg
Machine Dimensions	1200 x 800 x 1800mm	1350 x 950 x 1800mm

Frequently Asked Questions