Packserv's new Twin-Head Filler designed for Australian SMEs

In a move set to reshape how small and medium-sized manufacturers (SMEs) approach production, Australian packaging machinery specialist Packserv has developed an Australian-made PLC twin-head filling machine, purpose-built for local businesses that require digital technology, speed and simplicity without sacrificing floor space or budget.

Compact yet powerful, the new filler integrates Industry 4.0 technology into a practical format, making it suitable for space-conscious production lines. 

Designed and manufactured at Packserv’s Sydney facility, the machine has an intuitive HMI touchscreen that gives operators control over key parameters like fill volume, speed and nozzle configuration. Settings can be preloaded, allowing for quick and easy changeovers between different products and container types. This is designed to reduce set-up time and minimise waste from trial-and-error adjustments.

“Smart technology doesn’t have to be complicated,” said Nathan Wardell, Managing Director of Packserv. “We’ve developed this system to be operator-friendly and easy to learn because we know that many SME manufacturers have limited resources and time for training. The equipment must work quickly, reliably and with minimal downtime.”

The machine also includes real-time data capabilities, allowing manufacturers to monitor cycle durations and resource allocation across every shift. Built-in smart sensors adjust for variations in container shape and product viscosity, automatically maintaining fill accuracy and reducing the likelihood of spills or rejected units.

“This is where automation adds real value,” Wardell said. “By capturing and analysing performance data, SMEs can start identifying patterns, improve workflows and reduce resource usage. These are tangible benefits that help drive sustainable growth, without requiring a full-scale digital transformation.”

The twin-head filler is also fully compatible with other packaging machinery, including capping, labelling and conveying systems. Its modular design enables it to scale with a business’s needs, offering flexibility that many entry-level machines can’t match. As production ramps up or diversifies, the filler can be easily integrated into broader, semi- or fully automated lines.

Another key benefit is local support, with spare parts and technical assistance readily available.

“Keeping development in-house means we can respond quickly to customer feedback and continuously improve our equipment,” Wardell said. “Clients aren’t left stranded when they need service, parts or upgrades. It also keeps jobs and knowledge onshore, which is a win for everyone.”

For many SMEs, incorporating Industry 4.0 technology has felt like a future goal — complex, costly and out of reach. Packserv’s new twin-head filler challenges these assumptions. It’s a solution designed not just with automation in mind, but with real operators, factory floors and day-to-day production demands at its core.

“Innovation shouldn’t be out of reach,” Wardell said. “We believe that Australian-made machinery should lead the way by being reliable, accessible and built to meet the needs of our local manufacturing sector. That’s what this filler is all about.”