Quick answer
Gear-pump filling uses controlled pump rotation and can suit smooth pumpable products and flexible dose recipes. Piston filling uses a measured displacement and can suit viscous products and repeatable discrete doses. The better route depends on product lubricity, particles, shear, refill time and cleaning.
Side-by-side comparison
| Decision factor | Gear-pump filling | Piston filling |
|---|---|---|
| Dosing action | Controlled pump revolutions or time | Measured piston displacement |
| Flow profile | Can provide controlled continuous flow | Discrete suction and discharge strokes |
| Viscosity | Suitable range depends on pump size and torque | Broad range with suitable cylinder, valves and feed |
| Particles | Tight clearances can limit particles | Larger valves may handle particulates |
| Shear | Gear action may affect shear-sensitive products | Valve and piston movement also require assessment |
| Cleaning | Pump clearances and seals need attention | Cylinder, valves and seals need access or CIP design |
| Wear | Gears, bearings and seals | Piston seals, valves and cylinder |
| Dose change | Electronic recipe within pump range | Stroke or servo setting within cylinder range |
Decision checks
- Product viscosity, lubricity and abrasiveness
- Largest particle or inclusion
- Dose and nozzle count
- Required fill profile and anti-drip action
- Cleaning and dismantling frequency
- Pump torque or piston replenish time
- Wear-parts and service strategy
How to prove the choice
Test the least favourable product temperature and largest dose at full rate. Inspect repeatability, pressure, heating, shear, particles, cut-off and cleaning residues after a representative run.
Relevant specialist route
View the solutionpastefillers.co.ukPaste Fillers
Positive-displacement filling routes for creams, sauces, gels, pastes and viscous products.
Selection note: Do not select from a comparison table alone. Test representative product and packaging against a written acceptance plan.