How the Barrel-Filling Tote Assembly Works

This custom assembly is designed to accurately transfer fluid from Intermediate Bulk Container (IBC) into barrels or other containers. It combines an axial flow propeller pump, a positive displacement piston flow meter, a hose, a hand nozzle, and an electronic batch filling controller to provide repeatable, semi-automatic filling. 

1. IBC Tote

The product is stored inside the IBC tote and exits through its bottom outlet via a valve into the axial flow propeller pump. 

This chemical-resistant HDPE  270-gallon tote can hold as much liquid as six 55-gallon drums. A galvanized steel cage provides support to the IBC, helping maintain its shape under the weight of its contents. It also provides forklifts with easy moveability. It comes with a ball valve at the bottom of the tank to control the flow. 

2. Axial Flow Propeller Pump

The stored product enters the F427 axial flow propeller pump. 

The F427 axial flow propeller (AFP) pump is a type of centrifugal pump. These pumps use mechanical energy from the motor that transfers through the propeller, converting rotational energy into hydraulic energy that drives the flow and pressure of the fluid. These pumps move fluid parallel to the impeller’s shaft axis, with fluid entering and discharging axially.  

Thanks to their rotodynamic design, AFP pumps have a smooth, continuous flow with minimal pulsation. These pumps provide high flow and low pressure. They can handle low viscosity fluids - but we do have other designs for thick products. Keep in mind that these pumps must be primed with fluid in the system before starting. Dry running will result in wear to the blade edges. 

The F427 has a seal-less design reducing leakage risks, maintenance requirements, contamination, and overall cleanability. They have minimal dead zones, reducing the likelihood of contamination, and offering full COP compatibility. These pumps have a simple disassembly and can be taken apart completely.  

The pump moves the fluid to the piston positive displacement flow meter. 

3. Piston Positive Displacement Flow Meter

Immediately downstream of the pump is the TRIMEC piston positive displacement flow meter. This acts as the assembly's measuring device.  

Inside the meter, a piston repeatedly isolates fixed volumes of fluid through the measuring chamber. Each piston cycle represents a known volume, so as the number of piston cycles, the meter generates electrical pulse signals proportional to the volume of fluid passing through it and sends it to the batch controller. By counting the number of piston cycles, a flow measurement is obtained. 

For example:  

• one piston cycle = fixed volume.
• hundreds or thousands of cycles = total batch volume. 

Because the meter measures actual displaced volume rather than estimating flow from velocity, it provides excellent accuracy over a wide range of flow rates and viscosities. 

4. Batch Filling Controller

The assembly is controlled by a FLUXTRONIC FMC batch filling controller. The pulse output from the TRIMEC flow meter is connected to the FLUXTRONIC FMC batch filling controller, which is mounted inside the stainless-steel control panel. It receives these pulse signals from the flow meter, from which it then calculates the total volume dispensed and displays the measured volume. Together, the controller and the flow meter automate accurate preset-volume barrel filling. 

The operator can then select preset automatic batch quantities by using the display buttons. 

The key switch is used to access programming/setup mode, allowing authorized users to adjust or create preset fill volumes. Once the desired batch quantity is programmed, the key is returned to the operating position, preventing accidental changes. 

5. Filling Program

The control panel allows the operator to choose a programmed batch, which they can program by using the key to initiate programming/setup mode, through the display buttons. 

🟢 RUN 1 button  

First preset batch size (Ex. RUN 1 may dispense 53 gallons). 

🟢 RUN 2 button  

Second preset batch size (Ex. RUN 2 may dispense 59 gallons). 

🔴 NO FLOW indicator  

Illuminates if flow stops unexpectedly. 

🔴 OFF/ON illuminated selector switch. 

Main power to the filling system. 

The operator simply places the hand nozzle into the barrel and selects the desired preset. 

6. Vintner Reserve Hose

After leaving the flow meter, the liquid travels through the ContiTech Vintner Reserve hose. 

The ContiTech Vintner Reserve hose is reinforced with a spiral-plied synthetic fabric and a monofilament helix to help maintain its shape under pressure. The strength of these materials allows the hose to rebound to its original shape, unlike wire helixes that will remain flattened. The inner lining of the hose is made of EPDM for higher chemical and substance resistance.  

7. Explosion-Proof Hand Nozzle

The product exits through the dispensing hand nozzle into the receiving barrel or tank.  

This 316L hand nozzle has a Tri-Clamp connection for use with hoses with sanitary hose adapters. Its safety handle and swivel inlet with revolving balls guarantee absolute tightness even under pressure. 

While the operator controls the nozzle position, the controller continuously monitors the measured volume. 

8. Batch Completion

Throughout the fill, the FMC batch controller counts every pulse received from the TRIMEC flow meter. Once the programmed volume has been reached, the controller automatically opens a contact that de-energizes the motor and stops the pump. This allows the system to consistently dispense repeatable batch volumes with minimal operator intervention. 

System Flow

Specifications

Pump Type: FLUX F427 Sanitary Drum Pump.

Seal Type: No Seal in the Liquid Zone.

Motor Type: FLUX F457 IP24 Electric Motor.

Flow Meter: Trimec Piston Positive Flow Meter.

Hose Type: ContiTech Vintner Reserve Hose.

Nozzle Type: FLUX Explosion-Proof Hand Nozzle.

Batch Filling Controller: FLUX FLUXTRONIC FMC.

Tote: ClearSolv 270 Gallon (1000L) with Metal Cage.

Ball Valve: Ball valve.

Connection Type: 2" Tri-Clamp connection. 

Features

• Accurate batch dispensing.
• Repeatable filling cycles.
• Preset filling volumes.
• Automatic pump shutoff at target volume.
• Seal-less liquid zone.
• Pulsation-free flow. 

Applications

• Handles low-to-medium viscosity products (up to ~1,000 cPs).
• Suitable for flammable, hygienic, or sensitive liquids.
• Applications include high-proof alcohol, low-viscosity purees, oils, syrup, and more.