What Matters in Filling
Six factors that are crucial when designing a filling solution.
Dosing accuracy
- Reproducible Volumes Through Measurement and Control Technology
- Batch filling with stored profiles—even without a flow meter (FBM 4100 battery-powered motor)
- Calibration-accurate weighing technology in accordance with FPackV (FLUX FILL GT)
Media Resistance & Sealing
- Material selection based on resistance criteria. For example: temperature, concentration, and density
- Chemically resistant mechanical seals
- Parts in contact with media compliant with FDA and food safety standards
Process Safety & Explosion Protection
- ATEX-certified pumps and motors
- Grounding concept and antistatic hoses
- Zoning according to ATEX/IECEx
Ergonomics & Handling
- Lightweight pump sets with a cordless motor starting at 2.8 kg – cordless, portable (FBM 4100 cordless motor)
- Quick-release system for fast motor changes
- Ergonomic dispensing valves and discharge hoses
Cleaning & Media Replacement
- Short disassembly times for quick cleaning
- Media change without disassembly
- Short changeover times < 5 min
Documentation & Traceability
- Batch Logging via FLUXTRONIC®
- Digital data log for each filling operation
- Interfaces to MES/ERP systems
Filling Systems Comparison
Key performance indicators and features at a glance – for selection and comparison.
| FEATURE | MANUAL SYSTEMS | SEMI-AUTOMATIC SYSTEMS | FLUX-FILL GT | SAFETEC |
|---|---|---|---|---|
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| Dosing Method | Manual (dispensing nozzle) | Flow measurement | Weighing technology (FPackV) | Flow measurement |
| Automatic Stop | – | ✓ | ✓ | ✓ |
| Media Range | Universal, up to 30,000 mPas | Low to high viscosity | Low-viscosity, foaming, aggressive chemicals | Low-viscosity, aggressive chemicals |
| Container Types | Drums, IBCs | Drums, IBCs | All types of containers due to self-priming pump | All types of containers due to self-priming pump |
| Explosion Protection (ATEX) | ✓ (depending on configuration) | ✓ (depending on configuration) | – | – |
| Food Compliance | ✓ (depending on configuration) | ✓ (depending on configuration) | ✓ (optional) | – |
| Legal-for-Trade Accuracy (FPackV) | – | – | ✓ | – |
| Closed System | – | – | ✓ | ✓ |
| Ideal For | Simple manual filling operations | Simple semi-automatic filling, small batches | Filling sales containers in accordance with FPackV; also suitable for larger batches | Batch dosing processes; increased safety when handling aggressive media |
| View Product | View Product | View Product | View Product |
Operating Principle and Key Terms
A FLUX filling system transfers the medium from a source container—typically a drum or IBC—into the destination container via a drum or container pump. With manual sets, the operator controls the process using the dispensing nozzle.
- Battery-powered pump sets equipped with the FBM 4100 battery motor dispense via integrated batch filling—up to six volume profiles are stored in the motor and can be accessed at the push of a button, without the need for a flow meter.
- In semi-automatic systems, a flow meter (FMC or FMO) measures the dispensed volume; the FLUXTRONIC® control electronics compare the actual value with the target value and automatically stop the motor when the target volume is reached.
- In the legally metered FLUX FILL GT, a load cell controls the volume in accordance with the German Prepackaged Goods Regulation (FPackV); the system operates using the overfill method and is FPackV-compliant.
Quantity Control & Documentation
Filling with precise volume means more than just hitting the exact liter—repeatability, legally required documentation, batch logging, or audit trails are mandatory depending on the industry and sales format.
FLUX combines a pump, flow meter, and evaluation electronics into a modular system.
Quantity Monitoring
- FLUXTRONIC® + FMC or FMO
- ± 0.5% repeatability
- Industry, chemicals, cleaning batches
- Optional data export to MES/ERP
Mobile Batch Filling
- FBM 4100 Cordless Pump Set
- 6 preset flow profiles
- Without an external flow meter
- LCD display with real-time readings
Calibrated Filling
- FLUX FILL GT with weighing technology
- FPackV-compliant (sales packaging)
- Overfill method
- Calibration report for each batch
Sealed + documented
- SAFETEC Pump Set with MAGSON
- Hermetically sealed, no human contact
- Touch panel with filling profiles
- Audit trail-capable
Standards and Regulations
| Standard / Regulation | Scope | FLUX Solution |
| FPackV (Prepackaged Goods Regulation) | Filling of retail containers subject to calibration requirements in Germany | FLUX FILL GT |
| ATEX 2014/34/EU | Measurement and Control Technology in Hazardous Areas |
FLUXTRONIC®, FMC, FMO in explosion-proof versions |
Overview of Measurement Components
Filling Operations Across Industries
Filling tasks vary greatly by industry—the media, certifications, and level of automation differ.
Chemistry
Dosing acids, alkalis, and solvents—explosion-proof and tailored to specific materials.
Food & Pharma
FOOD- and 3-A-compliant filling of oils, concentrates, and liquid foods.
Pharmacy
FDA-compliant small-batch filling—APIs, suspensions, creams.
Cosmetics
Precise filling of lotions, tinctures, and perfume bases.
Paints & Lacquers
High-viscosity inks and coatings from 200-liter drums into a transfer tank.
Surface Technology
Dosing electroplating solutions and additives into process tanks.
Frequently Asked Questions About Filling
The FLUXTRONIC® control system with an FMC or FMO flow meter typically achieves a repeatability of ±0.5% when the system is calibrated. The actual accuracy depends on the medium, viscosity, flow rate, and switch amplifier configuration. For more stringent requirements (filling subject to calibration), the FLUX FILL GT with weighing technology compliant with FPackV is recommended.
Calibrated weighing technology in accordance with the Prepackaged Goods Regulation (FPackV) is required when the filled quantity is labeled for sale—that is, for prepackaged goods intended for the end consumer. The FLUX FILL GT operates using the overfill method with a calibration-accurate load cell and is designed for small and medium-sized batches.
Explosion-proof filling involves three levels: an ATEX-certified pump (materials, bearings, coupling), an ATEX-certified motor (compressed air or explosion-proof electric motor), and a grounding concept that includes antistatic hoses and equipotential bonding between the source and destination containers. The zone classification (Zone 0/1/2) is determined by the system and dictates the selection of components.
Yes. Manual pump sets can be retrofitted with a flow meter (FMC or FMO), a switching amplifier, and a FLUXTRONIC® controller. The pump and motor are generally retained—only the outlet fitting is replaced with the FLUX filling unit (FAE).
The SAFETEC pump set is designed for sealed hazardous-material containers with CDS or QC couplings. It empties the containers while they remain sealed via an immersion tube—without spilling a drop and without personnel coming into contact with the fluid. The self-priming MAGSON magnetic centrifugal pump operates with a hermetically sealed design.
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