Manual filling and packaging methods are not sustainable in today's competitive production environment. High labour costs and inconsistent quality make automation a necessity.
The semi-automatic and fully automatic filling systems developed by TÜRESAN make it possible to reach higher capacity with less manpower. PLC-controlled structures offer recipe storage and fine adjustment.
Investing in automation positively affects not only production speed but also product quality and the payback period of the investment.
Where manual filling loses money
Manual filling looks cheap until the hidden costs are counted: overfilling to be safe, underfilling that triggers complaints, rework, operator fatigue and output that changes from shift to shift. A filler specified at ±0.3% accuracy, such as the TÜRESAN liquid filling, powder filling and tablet counting systems, removes the safety margin from every container and repeats it thousands of times a day.
Semi-automatic or fully automatic: choosing the level
Automation is not all-or-nothing. A semi-automatic filler lets an operator place and remove containers while dosing is automatic, which suits low volumes and frequent product changes. A fully automatic line with conveyor, bottle cleaning, filling, capping, labelling and end-of-line stations runs with fewer operators and a stable output. TÜRESAN supplies both levels and designs the line so that it can be extended later.
PLC control, recipes and fine adjustment
A PLC-controlled line keeps a recipe for every product and container: filling volume, speed, capping torque, label position. Changing products becomes a matter of recalling the recipe, and fine adjustments are made on the panel instead of with tools. Servo-controlled dosing and servo-torque capping make these settings repeatable, which is what turns a fast machine into a reliable one.
Measuring the return on the investment
The payback of automation comes from several places at once: product saved through accurate dosing, labour hours released, fewer rejects, and the ability to take on larger orders without adding shifts. Because TÜRESAN handles engineering, manufacturing and integration under one roof, the line is sized for the real target output rather than for a catalogue figure, and it is supported from design to commissioning.
Manual, semi-automatic and fully automatic filling compared
| Aspect | Manual | Semi-automatic | Fully automatic |
|---|---|---|---|
| Dosing | By eye or scale | Automatic, ±0.3% on TÜRESAN fillers | Automatic, ±0.3% on TÜRESAN fillers |
| Container handling | Manual | Manual placing and removal | Conveyor with cleaning, capping and labelling |
| Operators | Several | One per machine | Fewer across the whole line |
| Product changes | Re-training | Recipe on the PLC | Recipe on the PLC |
| Best suited to | Trials, very small batches | Low volumes, many formats | Continuous production, growth targets |
Capacity figures for a specific line are calculated from bottle shape, number of nozzles and product viscosity during project design.
Frequently Asked Questions
Is automation worth it for a small producer?
Often yes, starting with a semi-automatic filler that removes dosing errors and can later be integrated into a full line. TÜRESAN sizes the solution to the actual output target.
How does a PLC recipe help in daily production?
Every product and container has stored parameters, so a changeover is a recall on the panel instead of a manual re-adjustment, and the settings are identical on every shift.
Does a fully automatic line need specialist operators?
Operation is done from the control panel and format parts are designed to be swapped without special tools. TÜRESAN provides commissioning and training with the line.
Can an existing filler be integrated into a new automatic line?
This is evaluated case by case during project design; conveyor, capping and labelling stations can often be added around an existing machine.
What utilities does an automatic line require?
TÜRESAN lines are specified for 380 V, 50 Hz, three-phase power and 6–8 bar compressed air.
