How An Explosion‑Proof Filling & Capping Machine Handles Multi‑Specification Packaging for Solvent‑Based Products

In the chemical industry, filling solvent‑based products is always a high‑risk operation. Typical end‑products include engine cleaners, brake cleaners, paint thinners, degreasers, adhesive solvents, graffiti removers, wood‑stain thinners and metal surface treatment fluids. These formulations often contain xylene, turpentine, cyclohexanone and other hazardous components, featuring low flash points, high volatility and electrostatic sensitivity, which may lead to safety hazards with improper handling. To make matters more complex, these products are often packaged in highly diverse containers — square cans, round cans, varying heights and neck diameters. It is challenging for a single machine to cover all these requirements.

Recently, we custom‑built a single‑head filling and capping production line for a Russian client, specially designed for explosion‑proof filling and capping of solvent‑based products. This case study may serve as a valuable reference for professionals working with similar products.

1. Client Requirements: Explosion‑Proof Performance & Multi‑Specification Compatibility in One Unit

The client’s filling materials are solvent‑based mixtures containing xylene, turpentine, cyclohexanone and other typical flammable‑explosive components, for finished goods such as engine cleaners, degreasers and paint thinners. Their core requirements are listed below:

• Full‑machine explosion‑proof compliance with IIBT4 standard

• Compatibility with multiple can types, including square and round containers

• Wide filling range: 60 ml – 5000 ml

• Filling accuracy: ±1%, throughput capacity: 20 L/min

• Automatic screw capping + automatic press capping with stable clamping force

• EAC marking for export to Russia

In short, this was not a standard off‑the‑shelf machine, but a non‑standard custom flexible explosion‑proof filling line.

2. Solution Design: Explosion‑Proof as the Bottom Line, Flexibility as the Core

2.1 Full‑Range Explosion‑Proof Configuration

The complete machine is engineered in accordance with the IIBT4 explosion‑proof standard, while the electrical control cabinet meets IICT4 rating. Key components adopt explosion‑proof specifications:

• PLC / HMI: Siemens integrated unit

• Solenoid valves & air cylinders: Airtac

• Explosion‑proof motors: Inovance

• Custom‑made explosion‑proof cable glands, explosion‑proof conduits and explosion‑proof mouse

All material‑contact parts including filling valves, three‑way flanges, fasteners and outlet fittings are made of 304 stainless steel. Seals are made of fluororubber / PTFE for superior solvent resistance against aggressive cleaners, thinners and degreasing fluids.

2.2 Filling System: Three Measurement Ranges within One Machine

The filling unit is equipped with:

• Automatic diaphragm pump feeding system

• 50 L material hopper

• One filling valve body

• Three sets of interchangeable filling valve outlet fittings: 100‑500 ml, 500‑2000 ml, 2000‑5000 ml

By swapping outlet fittings, the machine covers a filling scope from 60 ml to 5000 ml with accuracy maintained at ±1%, well‑suited for small retail cans of engine cleaner up to larger industrial‑size solvent containers.

2.3 Capping System: Combined Screw & Press Capping in One Process

The capping machine also complies with the IIBT4 explosion‑proof standard and supports the following functions:

• Manual or automatic cap feeding

• Automatic screw capping

• Automatic press capping

• Auto start‑stop control

Stable pressing force guarantees reliable sealing for European‑standard containers and matching lids, critical for volatile solvent‑based cleaners and thinners to prevent leakage and vapor escape.

2.4 Conveying System: 2 m + 2 m Layout with Manual Bottle Loading

• Filler section: 2‑meter conveyor with manual bottle loading (interface reserved for automatic bottle sorting)

• Capper section: 2‑meter conveyor

• 2‑meter conveyor each on upstream and downstream sides of the distribution unit

• Empty cans are manually placed and then automatically conveyed to the distribution station

2.5 Utility Requirements

• Compressed air: 0.4‑0.8 MPa; client to provide air compressor with minimum air consumption of 0.25 m³/min

• Power supply: 380 V, 50 Hz, three‑phase four‑wire

3. Compatibility with Multi‑Specification Cans

The client required one machine to handle various square and round containers for retail and industrial solvent products such as engine cleaners, degreasers and paint thinners. Container dimension specifications are shown in the table below:

（To maintain confidentiality of customer information, the data in the above table has been modified）

Overall machine adaptability: container diameter Φ30‑Φ148 mm, container height 60‑360 mm.

Thanks to the adjustable filling valve, adjustable conveyor and positioning mechanism, together with recipe‑based PLC control, operators can quickly switch between different can formats for engine cleaner, paint thinner and other solvent goods without major machine rework.

4. Delivery & Acceptance

Machine Model: HLZD‑1/YGJ‑826 | Quantity: 1 set
Order Date: Jul 10, 2026 | Delivery Date: Aug 10, 2026
For export to Russia with EAC marking.

Prior to shipment, we recorded and archived the following materials per client requirements:

1. Full‑machine operation demonstration video

2. Video tutorials for quick format changeover, plus drawings of each working station and pneumatic‑electrical circuit diagrams

3. Spare parts delivered together with the machine: one set of tools, three sets of sealing rings and one set of connectors

5. Case Summary

The core value of this project lies not merely in achieving explosion‑proof performance, but in realizing flexible multi‑container adaptability while maintaining full explosion‑proof protection for solvent‑based finished goods including engine cleaners, brake cleaners, degreasers and paint thinners.

For filling and capping of solvent‑based flammable‑explosive products, safety represents the baseline, precision provides process assurance, and flexibility creates competitive advantages. This custom non‑standard single‑head filling‑capping line meets IIBT4 explosion‑proof standards, covers 60 ml‑5000 ml filling volumes for various square and round containers, and satisfies Russian EAC certification requirements.

If you are working on filling & capping solutions for solvent‑based or flammable‑hazardous products such as engine cleaners, degreasers, paint thinners and industrial solvents, feel welcome to contact us for further technical discussion.