6. Can Syrups Be Filled Using Liquid Filling Machines? Which Filling Machines Are Best for Different Syrups? What Should You Know About Filling High-Viscosity Syrups?｜Neostarpack
Yes. Most room-temperature syrups—such as fructose syrup, vanilla syrup, caramel syrup, and brown sugar syrup—can be filled using the right type of liquid filling machine.
However, the filling solution must be selected based on syrup viscosity, crystallization tendency, production speed, and container type.
Syrups are generally medium- to high-viscosity liquids, which behave very differently from water-like products. To maintain stable flow, high filling accuracy, and proper hygiene, specialized filling mechanisms are required.
Neostarpack typically recommends gear-pump FG Series filling machines for syrup applications. Gear-pump fillers handle thick, slow-flowing syrups effectively and deliver stable, accurate, and continuous volumetric filling.
1. Which Filling Technologies Are Suitable for Syrup Products?
Depending on syrup viscosity and process requirements, the most commonly used filling technologies include:
1) Piston Fillers
Best suited for very thick, slow-flowing syrups and paste-like liquids.
Key advantages:
• High accuracy even when viscosity varies slightly
• Positive displacement ensures repeatable volume per cycle
• One of the most reliable solutions for high-viscosity products
• Neostarpack FP Series examples:
• FP1010 Big Volume Tabletop Piston Pump Liquid Filling Machine
• FP2100 Semi-Automatic Piston Pump Filling Machine
• FP1005 Semi-Automatic Benchtop Liquid Filler
• FP1002 Automatic Piston Filler (Small-Volume Dosing)
• FP5150 / CC4000 / LR3000 Chemical Filling, Capping & Labeling Lines
2) Gear Pump Fillers
Ideal for medium- to high-viscosity syrups such as fructose syrup, caramel syrup, and brown sugar syrup.
Key advantages:
• Smooth, stable flow control
• Excellent for continuous production
• High dosing accuracy for viscous liquids
• Neostarpack FG Series examples:
• FG1000 Semi-Automatic Benchtop Liquid Filling Machine
• FG1100 Semi-Automatic Servo-Driven Gear Pump Filler
• FG2100 Dual-Head Filling Machine
• FG5400 8-Nozzle Gear Pump Liquid Filler
• FG5650 Automatic Liquid Filling Machine
• FG5470-CS4150-LD4000 Fully Automatic Filling, Capping & Labeling Line
2. Key Conditions Required for Syrup Filling?
To maintain flow stability, filling accuracy, and food safety, a syrup filling machine should meet the following requirements:
1) Food-Grade Product Contact Materials
All components in contact with syrup should be:
•SUS304 or SUS316L stainless steel
•Food-grade seals and gaskets
•Designed for quick disassembly or CIP cleaning
This ensures compliance with food production and hygiene regulations.
2) Proper Filling Nozzle Design
High-viscosity syrups require:
•Larger-diameter nozzles
•Anti-drip or shut-off mechanisms
These features prevent stringing, dripping, and product buildup around the bottle mouth.
3) Filling Parameters Matched to Syrup Viscosity
To achieve accurate and clean filling, the system must be adjusted for:
•Appropriate filling speed (to avoid splashing)
•Nozzle size and geometry
•Pipeline resistance
For very thick syrups, pre-heating may be necessary to reduce viscosity and prevent residue buildup inside pipes and nozzles.
4) Does the Syrup Require Heating? (Important for Crystallizing Syrups)
If the syrup tends to crystallize—such as brown sugar syrup, caramel syrup, or concentrated fructose syrup—Neostarpack recommends:
•Heated or jacketed product tanks
•Temperature-controlled systems
Heating helps prevent crystallization, pipe blockage, reduced flow rate, and filling inaccuracies.
3. How to Choose a Filling Machine for Fructose Syrup or High-Viscosity Syrups
1) Match the Filling Technology to Syrup Viscosity
• High viscosity: Piston fillers or gear-pump fillers
• Medium viscosity: Gear-pump fillers
• Good flowability: Gravity fillers (often with mild heating)
2) Choose Based on Accuracy Requirements
•Retail bottled products requiring high accuracy:
→ Piston or gear-pump filling systems
•Industrial containers or bulk packs:
→ Weight-based filling systems may be considered
3) Select Based on Production Capacity and Automation Level
•Low output: Semi-automatic filling machines
•Medium to high output: Fully automatic filling lines
(including bottle feeding, capping, labeling, and coding)
Automation planning should consider:
•Required bottles per minute
•Future container size changes
•Potential capacity expansion
4) Packaging Compatibility and Cleaning Requirements
Before selecting equipment, confirm:
•Compatibility with PET, glass, and HDPE containers
•Production line layout and available floor space
•Whether CIP or quick-clean designs are required
4. Syrups Can Be Filled with Liquid Filling Machines—If the Right Equipment Is Chosen
Standard syrups:
→ Can be filled using Neostarpack gear-pump FG Series or piston filling machines.
Highly concentrated or crystallization-prone syrups:
→ Recommended to use filling systems with heated tanks or temperature control.
Without proper evaluation of syrup properties—such as viscosity, crystallization behavior, and temperature sensitivity—manufacturers may encounter:
•Unstable flow rates
•Dripping and stringing
•Product buildup or pipe blockage
•Large filling-volume deviations
For reliable production capacity and consistent product quality, it is essential to match the filling equipment precisely to the syrup’s characteristics and production requirements.
Need a Complete Filling Solution for Syrups or High-Viscosity Products?
📩 Contact Neostarpack for a consultation: info@neostarpack.com
We provide syrup filling machines, high-viscosity liquid filling systems, and fully integrated automated filling and packaging lines.
Further Reading
1. How to Choose the Right Oil Filling Machine
2. Do Liquids Need to Be Filtered Before Filling? Do Filling Machines Include Filtration?
Our suggestion is to provide a sample test before purchasing the filling machine.
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