5 Things to Know Before Buying Liquid Packaging Solutions

Jul. 28, 2025

Liquid Chemical Packaging Solutions Guide

When it comes to finding the right liquid chemical packaging solution for your organization, you cannot simply select the first container you find that seems appropriate. The size and material of liquid packaging containers can play a large role in how safely and reliably your chemicals are stored and/or transported.

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Even the elements of heat, cold, and UV rays can affect the type of packaging that is suitable for your operation. This comprehensive guide will go over the most important aspects of liquid packaging and explain the importance of working with an expert to find the best solution for your needs.

Considerations For Packaging Liquid Products

The first step in identifying the best packaging solution for various liquid chemicals is to understand the specific properties of the chemical in question. The chemical bottling procedure that works for one substance may vary completely from another substance, even if they are similar at the molecular level.

At a minimum, know the following properties and how they affect your choice in liquid chemical packaging.

Temperature

Liquid chemicals must be filled and stored at the proper temperature required to maintain stability. Excessive heat or cold may impact the chemical’s performance for the end user. Additionally, certain chemicals also require specialty packaging machines engineered to perform within a certain temperature range. Use the correct machine to ensure the bottling process is smooth from start to finish without any delays or downtime.

Viscosity

Viscosity plays a large role in liquid packaging since it affects three important aspects of the bottling process. The rate at which the chemical dispenses for bottling and packaging is heavily impacted by the viscosity of the chemical. The type of bottle filling machinery used for a chemical must be carefully selected, especially if the chemical is hazardous. The machine must use enough force to fill the bottle without causing splatters or overfilling.

Particulates

If your end liquid product contains particulates, you must consider their impact on the bottling process. The average size of particulates will determine the type of machinery used to fill the containers. The filler must be able to dispense the liquid product and the particulates seamlessly into the container. Otherwise, errors can occur during the bottling process.

Container Size

Once you know the viscosity and temperature of your liquid chemical and size of any particulates, you can move on to determining the proper size for your liquid packaging containers. Container sizes can vary greatly, from just one ounce to millions of gallons. The size of the container will largely be determined by your needs and how you are transporting your liquids.

The most common sizes of small and bulk liquid packaging containers include:

1 Pint
1 Quart
0.5 Gallon
1 Gallon
2.5 Gallons
5 Gallon Pail
5-20 Gallon Drums
20 to 55 Gallon Drums
275 Gallon IBC Totes
330 Gallon IBC Totes

Material Options for Liquid Packaging Containers

Numerous material types are available for liquid chemical bottling. Some materials can support various chemicals (even hazardous ones) while others will be limited to a select few.

Intermediate Bulk Containers (IBC)

For bulk liquid packaging, IBCs are the perfect answer. They can be made of plastic or metal, and vary in flexibility. These pallet mounted containers allow for safe and secure shipment of most types of chemicals in large quantities.

Plastic

Plastic is widely used for chemical bottling because it is sturdy and cost-effective. Plastic is less sustainable than other options, but can hold a wide range of chemicals, meaning it’s often a default choice for manufacturers.

Glass

Glass has long been used for small amounts of liquid in need of packaging. It does not corrode, and it provides a safe barrier to store chemicals. It can even be tinted, which is important for photosensitive chemicals. However, glass can easily break and must be handled with great care.

Carbon or Stainless Steel

Metal is an exceptional choice for storing and shipping flammable and combustible liquids. Even most solvents can safely be stored in metal containers. Most commonly, oil, gasoline and petroleum are shipping in metal 55 gallon drums. It is important to note that metal can corrode over time, and it must also be grounded/bonded to prevent igniting a flammable chemical.

Lined Drums

Certain types of chemicals react with metal drums, which indicates a barrier needs to be placed between the container and the chemical. An epoxy lacquer is used to coat the inside of the drum to protect the chemical from any reaction. The pH range for lacquered line drums is limited, so not all chemicals can be stored in this type of container.

Potential Liquid Packaging Hazards

When handling chemicals, challenges and hazards must always be taken into consideration for the safety of employees, shipping crews and customers. Before beginning your liquid packing services, you must identify hazards and determine the packaging capabilities required to handle your specific needs. Some of the most common hazards related to liquid chemicals include the following:

Physical Hazards

Some liquids or chemicals can pose threats known as physical hazards, such as burns, if they come into contact with the skin. These types of chemicals should also be handled by a liquid packaging machine to ensure human interaction (and risk of injury) is limited.

Health Hazards

Any toxic hazardous chemicals must be packaged by a bottle filling machine. These chemicals pose numerous health concerns, so the amount of human interaction must be kept to a minimum.

Environmental Hazards

Your liquid packaging company must remain in compliance with the EPA. Certain chemicals can cause extreme damage to the ecosystem if they leak during shipment or while in storage. The right containers must be selected to ensure any environmental damage is minimal.

The company is the world’s best Liquid Packaging Solutions supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.

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Partnering with a Liquid Chemical Packaging Expert

If you have your chemical or blend ready for production, but simply aren’t 100% sure you know which size container to use, you may want to consider partnering with a contract manufacturer for your packaging needs. A chemical contract manufacturer, or toll blender, is staffed with industry experts with the experience to know what works and what does not. Rather than going through trial and error, you can ensure you have the right liquid packing solution from the start.

Additionally, while this guide has covered all the bases of liquid chemical packaging solutions, each organization and their chemical bottling needs are unique. Things beyond your packaging, like R&D, logistics and product formulas require custom planning to ensure the chemical or blend remains stable from filling through shipment and to the final end user.

If you are looking for a contract manufacturer to partner with your organization, Royal Chemical is here for you. We can assist you with every step of the process and identify the solutions that are best suited or your organization.

Choosing a Liquid Filling Machine? 5 Things You Must Know!

All you want to do is buy the right liquid filling system. But no, nothing can be easy or straightforward nowadays… can it? So whatever industry you’re coming from, we know there are a lot of things to consider when trying to find the best solution for your needs. Today, we are going to briefly discuss the “5 Things You Must Know” when looking your liquid filling machine.

1. What is your desired fill rate?

One of the more important things to consider when choosing your liquid filling machine is your fill rate. How much do you want to fill per minute, per hour, per day and overall per month?

This is an important area of determination since it will also help in identifying the right level of automation for your needs. That is, filling a 5-gallon container vs a precision vial fill application is probably going to require a different type of filling solution. These types of details will also help with determining your setup options as it relates to your metering system, aka liquid filling pumps.

2. What type of liquid product do you have?

Sounds simple enough… what type of liquid product do you have?
Being able to clearly describe your liquid product as very viscous, semi-viscous, or a very fluid, water-like product, will go a long way in helping to match your production needs with the best solution.

Your type of liquid product may also require a specific environment. A level of cleanliness, or even system design may be something that needs to be taken into consideration; especially, when you are dealing with pharmaceutical, diagnostic and biotech environments. Aseptic filling, which means the product needs to be filled within a sterile environment, vs non-aseptic filling, so those basic, but very important details should be noted within your overall application.
When dealing with specialty chemicals, you may also have to consider if the product is flammable and requires an explosion-proof filling system. There are certainly stringent rules and regulations regarding how these types of flammable liquids need to be handled in a manufacturing and production environment.

3. What type of containers are you filling?

When dealing with liquid filling applications, what you put your liquid product into is just as important as the product itself.

There is a world of different bottle shapes, sizes, and types of associated caps as it relates to closing/capping requirements. You can muddy the waters even more, if you will, should your container require a fill stopper crimp cap, fill cap, press on cap, twist on, spray bottles, or even an atomizer spray – all completely doable, but certainly needs planning ahead and constant dialogue amongst the project team members. Liquid packaging can have a vast array of possible and creative solutions, but also pitfalls, if unaware.

Another part of the container aspect is understanding any labeling requirements. How difficult or easy is it to label your container’s surface? Also, what type of labeling solution do you want – a fully-automated, integrated labeler, or a standalone system? You can certainly incorporate whichever solution you prefer, but uncovering these needs ahead of time will ultimately save you time and money as you complete your project. If you’re seeing a theme, you are clearly ahead of the game… constant communication and planning ahead will always serve you well.

4. What level of automation do you want?

If you’ve already answered your initial question, “Q#1: What is your desired fill rate”, you’ve already taken a big step in determining what level of automation is best for your application.

For example, if you are filling about 5,000 bottles a day, or roughly 10-12 containers per minute, a Benchtop solution may best fit your needs. Whether a single or dual nozzle, a handheld semi-automatic Benchtop filling machine could be an excellent solution for your needs – an affordable, quality and workhorse solution.

Now let’s say your production requirements have you filling about 25,000 bottles per day, or roughly 50-52 containers per minute. Here, you may want to increase your production throughput by considering a slightly higher level of automation with an intermediate inline filling system, or even a higher output scenario with a larger Monobloc design. Of course, as you increase your levels of automaton, there are certain costs associated with those greater mechanical and electrical elements

Going back to your specific filling requirements, these different levels of automation may/may not make sense. Therefore, it’s important for your project team to be on the same page as it relates to your liquid filling application.

5. What is your available floor space?

Often overlooked until the later moments, another important aspect to consider when choosing a liquid filling system is your available floor space. You must accurately know your available clean room, laboratory or facility floor space. A bad scenario… you purchase an expensive production line that does not fit into your clean room or overall floor space – not good.

When determining your floor space, or the required footprint of your liquid filling machine, be sure to also factor in your human element as well. That is, your operators as well as any necessary space for inventory and supplies.

Of course, there are many other details to consider when looking for the right liquid filling solution for your needs. Just to name a few, lead times, available budgets, as well as specific industry requirements like fill accuracies may also help determine what type of liquid filling solution is right for you.

The best thing to do is not go on this journey alone. Do your homework, research a few companies, talk with their representatives, share relevant, appropriate details regarding your application, and be sure to prepare and understand the “5 Things You Must Know” when choosing your liquid filling system. For more information on liquid filling, capping and labeling solutions, please or call 866.258.. Visit >" href="https://www.filamatic.com/index.php" target="_blank">www.filamatic.com

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