Part 2 of our series: Identifying and resolving issues during honey filling

In this second part of our troubleshooting series, we take a closer look at typical symptoms that can occur during honey filling — and show you how to resolve them quickly and effectively. Whether it’s a dripping nozzle, air bubbles in the jar, or fluctuating fill levels: many issues can be resolved with just a few simple steps and the right know-how.

1 Honey drips from the nozzle after filling

Possible Causes and Solutions:

  • Loose or leaking connections: Check that all screws on the lid are hand-tight and that the sealing rings in the pump head are intact.
  • Tip: We recommend replacing all seals every 20,000 kg or at least once a year.
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  • Worn filling nozzle: The filling nozzle needs to be replaced.
  • Supply tank is positioned too high: Lower the supply tank so that the filling nozzle of your Honeyaid® filling machine is at least 10 mm above the liquid level in the tank.
  • Check valve is missing or incorrectly installed: Make sure the check valve is correctly mounted.

2 Air bubbles in the jar

Possible Causes and Solutions:

  • Retract setting is too high: This causes air to be drawn into the nozzle. Reduce the retract value.
  • Air entering the system: Check all critical connections for tightness: Check valve – hose, Hose – pipe bend, Pipe bend – pump head, Pump head – lid, Pump head – filling nozzle.

3 Honey leaking from the back of the pump head

Possible Cause: The shaft seals in the gear pump head are damaged or worn.
Warning: Honey may enter the motor and cause damage.

How to fix it: Replace the shaft seals immediately.

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4 Honey leaks from the nozzle after downtim

Possible Cause: The supply tank is positioned too high, creating excess pressure on the pump head.

How to fix it: Lower the supply tank or raise the machine. The liquid level in the tank must be at least 10 mm below the wedge-shaped nozzle. Important: If using a disc valve, be sure to close it during longer downtimes of the filling machine.

5 Air enters the pump head through the wedge nozzle during downtime

Possible Cause and Solution:

  • Product is flowing back into the supply tank: Check the check valve for leaks or incorrect installation.

6 Honey foams inside the jar

Possible Causes and Solutions:

  • Filling speed is too high: Reduce the motor speed. If necessary, use a larger filling nozzle.
  • Leaks in hose/pipe connections or in the pump head: Check all screw connections for hand-tightness and ensure that all seals are intact.

7 Fill quantity fluctuates

Possible Causes and Solutions:

  • Leaks in the system: Tighten hose clamps and check seals in the pump head and check valve.
  • Wear on the pump (e.g., gears or seals): Replace worn parts promptly.

Note: We’ll be happy to send you instructions for replacing the seals.

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8 Decreasing fill volume over time

Possible Cause: As the level in the supply tank drops, the pressure on the pump decreases.

How to fix it: Recalibrate the filling machine regularly to compensate for pressure changes.

9 Small air bubbles in the upper part of the pump head – Inaccurate fill volume

Possible Causes:

  • The product does not flow quickly enough through the hose and pipe bend (especially affects rapeseed honey).
  • The product is too cold or too viscous.

How to fix it:

  • Warm the product to reduce viscosity.
  • Keep the hose as short as possible.
  • Raise the supply tank to improve flow into the pump.
  • Reduce motor speed to approx. 40 rpm to allow smoother product flow and match the filling speed of the machine.
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