Introduction: The Rise of Healthy Cooking Sprays
In the bustling kitchens of Panama City and beyond, a culinary shift is happening. Health-conscious consumers are moving away from heavy, poured oils and embracing the precision of cooking sprays. Whether it’s premium avocado oil, extra virgin olive oil, or canola blends, the market demands convenience, portion control, and purity.
For our client in Panama, this market shift presented a massive opportunity—but also a logistical nightmare.
While demand was sky-high, their production floor was stuck in the past. This is the story of how they transformed a bottlenecked, labor-intensive manual operation into a streamlined, automated powerhouse using Aile Automation's BOV Aerosol Filling Machine.
The Challenge: The "Bottleneck" of Manual Labor
Six months ago, walking into the client’s facility felt less like visiting a modern manufacturing plant and more like stepping into a busy commercial kitchen.
1. The Speed Limit
The process was entirely manual. Workers used measuring cups and funnels to pour oil into cans. It was slow, tedious, and physically exhausting. On their best days, the team could barely manage 1,500 bottles. During peak seasons, orders piled up, and lead times stretched from days to weeks.
2. The "Messy" Reality of Oil
Edible oil is notoriously difficult to handle manually. It drips. It spills. It coats the outside of bottles, requiring extra labor just to wipe them down before labeling. This wasn't just a cleanliness issue; it was a safety hazard and a massive waste of expensive raw materials.
3. The Quality Control Nightmare
In the premium food industry, consistency is king. With manual filling, one bottle might contain 255ml while the next held 245ml. Furthermore, without proper pressurization technology, the spray effect was inconsistent—sometimes a mist, sometimes a stream.
They needed a solution that could handle the viscosity of oil, ensure food-grade hygiene, and drastically increase throughput without expanding their workforce.
The Solution: Why Bag-on-Valve (BOV)?
The client knew they needed to upgrade to Bag-on-Valve (BOV) technology. Unlike traditional aerosols that mix gas (propane/butane) with the product, BOV separates the two.
- The Product: Sits inside a multi-layer vacuum bag.
- The Propellant: Compressed air or nitrogen sits outside the bag, inside the can.
This means the oil never touches the air (preventing oxidation) and never mixes with chemical propellants. It is the gold standard for edible oils.
However, European machinery was outside their budget, and other Asian alternatives lacked the build quality they required. That’s when they discovered Guangzhou Aile Automation Equipment Co., Ltd.
The Game Changer: Aile’s Automatic BOV Filling Machine
The client selected the BOV Aerosol Filling Machine, a compact yet powerful unit designed specifically for this type of application.
Here is how this machine solved their specific problems, backed by the technical specifications:
1. From 1,500 to 8,000 Per Day
The most immediate impact was speed. The machine is rated for a production capacity of 700 to 1,000 fills per hour.
- Before: ~200 bottles/hour (Manual team)
- After: ~800+ bottles/hour (One Machine)
In a single 8-hour shift, the client went from struggling to finish 1,500 units to easily clearing 6,000+ units. The machine features a robust pneumatic system with a maximum air consumption of just 0.6m³/min, making it energy-efficient despite its high output.
2. Precision Where It Counts
Wasting premium avocado oil is expensive. The Aile machine boasts a Liquid Repeat Filling Accuracy of < 1.0%. Whether filling small 80mm cans or large 250mm restaurant-sized cans, the dosage is exact.
3. Simplified Operation for Local Staff
One of the client's biggest fears was complexity. "Do I need a computer engineer to run this?"
The answer was no. The machine features a user-friendly PLC Control System with a clear Touch Screen (HMI).
- One-Button Start: Operators simply turn the Power Rotary Switch and hit the green Start Switch to begin automatic production.
- Visual Monitoring: The screen displays real-time production counts ("Current Output") and allows for instant "Zero Clearing" to track batches.
- Safety First: The system includes a prominent Emergency Stop Switch that instantly halts all electrical parts and cylinders if an issue arises, ensuring worker safety.
The Implementation Process
Transitioning from manual to automatic was seamless. The machine's footprint (1000 x 600 x 1600mm) is surprisingly compact, allowing it to fit easily into their existing limited floor space.
The Workflow:
- Loading: The operator places the can with the valve already inserted into the holder.
- Vacuum & Gas Filling: The machine’s head descends. The "Suction Valve" engages to remove air, creating a vacuum. Immediately, compressed air (or nitrogen) is injected to the precise pressure (0.50-0.70 MPa).
- Crimping (Sealing): The Sealing Cylinder engages. The machine ensures a perfect seal depth of 4.8-5.2mm and a diameter of 27.5mm, ensuring no gas leaks.
- Liquid Filling: Finally, the high-viscosity oil is forced through the valve into the bag. The "Filling Delay" and "Perfusion Reset Time" are perfectly synchronized to prevent drips.
The Result: The "Spray Test" Proof
The ultimate test of a BOV machine is the spray quality. If the pressure isn't balanced or the filling is inconsistent, the oil will "spit" or stream.
As seen in our case study video, the results were flawless.
When the operator performed the Oil Spray Test on the cardboard:
- Atomization: The oil emerged as a fine, wide-angle mist.
- Coverage: Even distribution without heavy droplets.
- Consistency: Continuous spray from start to finish.
This quality allowed the client to market their product as "Professional Chef Grade," opening doors to high-end supermarkets that previously rejected their hand-filled products.
Conclusion: Is Your Production Line Ready for an Upgrade?
This Panama case study proves that you don't need a massive factory footprint or a million-dollar budget to achieve world-class packaging standards. By switching to the Aile BOV Filling Machine, our client:
- Reduced Labor Costs by 70%.
- Increased Daily Output by 400-500%.
- Eliminated Product Waste (Accuracy < 1%).
Whether you are packaging edible oils, cosmetic sprays, or medical saline solutions, the transition to automation is easier than you think.
Ready to transform your production line?
Contact our engineering team today!
For a free consultation and a virtual demo of the AILE BOV Filling Machine.
