Juice Bottling Line

1. The whole juice bottling plant includes juice blending and preparation system, bottle feeding system, bottle disinfectant and rinse system, bottle cap disinfect and washing system, juice bottling system, juice bottle sealing system, juice bottle conveyor system, bottle juice cooling tunnel, bottle sleeve label machine, date coder on bottles, bottle shrink packing machine.
2. The bottled juice production line has high compatibility, flexibility and efficiency, stable performance. It can fill PET bottles volume from 250-1500ml only if the bottle neck and bottle material is the same; The filling and production process is controlled by one electronic control cabinet, which can guarantee synchronization of production line operation.
3. After the juice is prepared and sterilized, it is directly pumped to the filling machine for filling in a closed pipeline to ensure that the juice product is not contaminated; use chlorine dioxide or hydrogen peroxide to sterilize the empty bottle and bottle cap to ensure the filling container is clean and hygienic; The filling workshop is isolated from other systems for air purification treatment to ensure that there is no source of pollution during the filling process.
4. In full bottle conveyor, it is equipped with central oil lubricate system, which can ensure that the bottles are transported steadily on the conveyor line without falling down.
5. According to the bottle shape and clients’ requirements, the bottle labeling machine has a high degree of flexibility. It can use sleeve labels, self-adhesive labels or cold glue labels. The number of labels is 1-3, which can be affixed to the bottle body or the mouth of the bottle.
6. After the juice is filled into bottles, in order to prevent the juice from being heated for a long time, a spray cooling tunnel is used to cool the juice to room temperature before packaging.
7. The juice bottling plant is controlled by PLC, all machine running is synchronous and high efficiency.
8. You can check the FAQ of the juice bottling plant here

Project name： PET or glass bottle juice bottling plant

Capacity: 6000BPH-25000BPH based on 500ml bottles

Filling products: PH＜4.5 Acid fruit juice

Filling temperature: 85-92℃ hot filling or 65-75℃moderate temperature filling

Applicable bottle diameter:55-110mm, Applicable bottle height: 160-310mm

Applicable bottle shape: Round bottles, if for the square bottles, the juice bottling machine need to add bottle dividing system

Bottleneck diameter: 28mm or 38mm

User environment requirements: Temperature: 10～40℃ Humidity: no condensation

User voltage requirements: 380V/50HZ, three-phase or customized.

The sterile gas filter unit uses imported gas filters to remove impurities and even bacteria in the compressed air, ensuring that the gas after the gas filter reaches the clean standard, and provides gas that meets the requirements for blowing the cap.

Before preparing aseptic gas, the filter element needs to be sterilized with steam, and the pipeline behind the aseptic filter also needs to be sterilized. After the above conditions are completed, the aseptic gas can be prepared.

The compressed air passes through a pre-filter (5 inches), the filter element is polypropylene fiber (0.3μm); then it passes through the sterilization filter (5 inches), the filter element is PTFE (0.01μm).

The concentrated chlorine dioxide solution and water are added to the storage tank. According to the concentration set by the machine, the system adds a certain amount of sterilizing liquid stock and water to the tank to achieve the use concentration.

The chlorine dioxide solution circulation process: the sterilizing solution is returned to the recovery tank installed near the filling machine, and then circulated to the sterilizing solution preparation system through a centrifugal pump; or the sterilizing solution is directly returned to the sterilizing solution preparation system. The recovery system is used when chlorine dioxide is used in the production process and the external sterilization stage.

The concentration of the disinfectant in this system is detected by manual titration (customers can choose an online disinfectant concentration detection instrument according to their needs), and the concentration of disinfectant and water is manually added according to the concentration to ensure the stability of the concentration of the disinfectant in the system.

Configuration instructions: The blending system is mainly composed of blending unit (storage tank (with stirring), dosing pump); disinfectant delivery unit; filter unit; electrical control unit, etc.

Juice bottling machine is the core process of the juice bottling plant. The bottle directly enters the bottle-feeding wheel with the function of separating bottles through the air conveyor, and is transferred from the bottleneck of the bottle-feeding wheel to the bottle washing machine. The rotary plate of the bottle washing machine is equipped with a bottle mouth type stainless steel bottle clamp. The bottle clamp clamps the bottle mouth and flips 180° along a guide rail to make the bottle mouth downward. In a specific area of ​​the bottle washer, a special dedicated nozzle sprays bottle-rinsing water to rinse the inner wall of the bottle. After the bottle is rinsed and drained, the bottle is clamped by the bottle clamp and then turned over 180° along the guide rail, so that the bottle mouth is upward. The washed bottle is exported from the bottle washer (1) through the transition wheel and sent to the bottle washer (2): after the same process of rinsing as the bottle washer (1); the washed bottle is transferred through the washing machine by star wheel. The bottle entering the filling machine is held by the bottle holder. The filling valve is lowered and raised through the valve lifting mechanism under the action of the cam. During filling, the filling valve is lowered to contact the bottle mouth and then opened to complete the filling process. After filling, the filling valve rises away from the bottle mouth under the action of the cam, and the bottle enters the capping machine through the bottleneck transition wheel. The anti-rotation knife on the capping machine jams the bottleneck to keep the bottle upright and prevent it from rotating. The capping head keeps revolving and rotating on the capping machine, and realizes the actions of cap grasping, cap covering and cap screwing under the action of the cam, completing the entire capping process. The cap arranging device is located above the capping machine, and is connected with the capping machine dial plate through the capping guide rail. The finished bottles are transferred from the capping machine to the bottle-out conveyor chain through the bottle-out wheel, and then sent out of the four-in-one filling machine by the conveyor chain to enter the next process.

1) Bottle feeding mechanism

•  The bottle feeding method in which the air duct is directly connected to the bottle feeding wheel.
•  The bottle feeding wheel adopts an innovatively designed bottle mouth clamping mechanism with bottle separation function, eliminating the bottle feeding screw and conveyor chain, and changing the bottle shape does not require changing or adjusting any parts.
• Equipped with a pneumatic bottle blocking device.

2) Disinfectant, sterile water bottle washing machine

•  The rotating disc is all welded with stainless steel ANSI304.
• The flip-type bottle clamp is used to block the bottleneck, avoiding the possible contamination of the threaded part of the bottle mouth caused by the rubber clamp block on the traditional bottle clamp. The bottle clamp is made of stainless steel ANSI304, which is hygienic and durable.
• Using high-efficiency spray nozzles, the bottle-rinsing water is sprayed at a set angle, which can be flushed to any part of the inner wall of the bottle, flushing thoroughly and saving bottle-rinsing water.
• Both the bottle clamp and the sliding sleeve of the turning mechanism adopt German igus corrosion-resistant and maintenance-free bearings.
• The power of the bottle washing machine is transmitted by gears through the transmission system in the frame.

3) Transition wheel

• It adopts the form of a steel dial wheel to lift the bottle mouth. It does not need to adjust the height of the equipment to change the bottle shape, and there is no need to change any parts when the bottle diameter is not much different.

4) Bottle Juice Filling machine

•  The rotating disc is all made of stainless steel ANSI304.
• The filling valve is made of ANSI304.
• Using high-precision, high-speed quantitative filling valve, the liquid level is accurate and no liquid loss.
• There is a temperature detection device on the feed pipeline, low-temperature shutdown and high-temperature alarm.
•  The adopted CIP cleaning system ensures that the filling system of the whole machine is clean to meet the requirements of the hot filling process.
•  The power of the filling machine is transmitted by gears through the transmission system in the frame

5) Bottle Capping machine

• Magnetic constant torque capping head, the capping effect is stable and reliable, and the capping defective rate is less than 0.2%.
•  The cap-dropping rail is equipped with a mechanism for preventing the reverse cap from passing through and removing the cap. At the same time, it is equipped with a set of photoelectric switches. When there is no cap on the cap-dropping rail, the machine will automatically stop, which can effectively avoid the appearance of uncapped bottles.
• The capping machine is equipped with a bottle inlet detection switch, and the cap locking cylinder at the connection between the cap falling guide and the cap dial controls the discharge of the cap in a chain to ensure that the cap is stopped when there is no bottle, and the loss of the cap is reduced.
• Efficient centrifugal cap sorting method, with less cap abrasion.
• The cap sorting device is equipped with a cap missing detection mechanism, which is used to control the start and stop of the bottle cap elevator.

6) Bottle discharge dial/starwheel

•  The bottle bottom conveying method is adopted, and the bottle bottom supporting plate is a spiral descending curve. Changing the bottle shape does not require adjusting the height of the machine and the bottle conveying chain.

7) Machine Rack

• The frame is welded by high-quality carbon steel, and the surface is treated with rust prevention and spraying, and the surface is covered with stainless steel plate (ANSI304).
• Exclusive use of stainless steel countertop through-hole tensile structure, with O-ring seals, so that all bearing seats and support shafts on the countertop can reduce leakage to zero.
• The transmission system of the four-in-one machine is located under the table top of the frame and adopts gear transmission.
• The transmission gear adopts a cross arrangement of steel gears and nylon gears.

8) Control system

• PLC automatically completes the entire process control of the five-in-one filling machine from bottle in to bottle out.
• Using touch screen operation, production speed, shift output count, fault category, fault occurrence point, etc. are all displayed on the screen. It can also automatically count the time of failure, failure category and other information.

The cap sterilizer’s main function is to rinse and dry the bottle caps from the capping device or capping machine, and finally send the caps to the capping machine. The cap disinfection machine is divided into three areas according to the process flow: disinfectant spray area, cap flushing water spray area, and sterile air drying area. The bottle caps are rinsed and blow-dried in these three areas.

1) Efficient centrifugal cap sorting method, with less cap abrasion.

2) Equipped with a bottle cap detection mechanism to control the start and stop of the bottle cap elevator.

3) There is a mechanism for preventing the reverse cover from passing and removing the reverse cover on the cover drop guide of the cover sorter.

4) Arrange the nozzle positions reasonably, and are equipped with imported high-efficiency spray nozzles, so that the bottle caps can be fully rinsed.

5) Effectively isolate the water jetting area and sterile air jetting area to avoid the occurrence of water stringing and ensure the drying effect.

6) The bottle cap runs smoothly and meets the requirements of high-speed filling production lines.

7) Manual and pneumatic valves are installed on the pipeline, which is simple and convenient to control.

8) The proximity switch on the cap sorting device automatically detects the cap throughput and is used to control the start and stop of the cap elevator.

9) If a reverse cap enters the cap drop guide, the reverse cap star wheel on the cap drop guide will be jammed, and the reverse cap photoelectric switch detects the reverse cap signal, and an alarm prompts the operator to take out the reverse cap.

The capping elevator is mainly composed of three parts: the cap containing bin, the cap conveying belt and the cap conveying air pipe. The cap in the cap bin drops to the cap conveying belt through the discharge opening at the bottom of the cap bin. In order to ensure the smoothness of the cap outlet, a small-range agitating device is installed at the cap outlet. The cap on the cap conveying belt is sent to the cap conveying duct by the belt. Under the action of the wind of the fan, the bottle cap is conveyed to the cap sorter through the conveying pipe to achieve the purpose of conveying the bottle cap. All materials are made of SUS304 material to ensure sanitation and cleanliness and simple appearance. The cap bin is equipped with a missing cover detection signal, and the indicator light will light up and give an alarm when the cap is missing.

The conveying line is composed of several conveying unit modules. Each unit module can be configured and connected according to the requirements of the actual production line. It mainly includes a basic conveying unit, a pressureless conveying unit, a bottle storage platform, etc., which play a role in the entire production line. The transportation and storage functions of the container enable the container to be transported between the individual machines in the filling production line.

Chainplates of different materials are used for different conveying containers, plastic steel chainplates are used for PET bottles, and stainless steel chainplates are used for glass bottles or cans.

During the conveying process of the high-temperature filled juice, the bottle is automatically poured on the bottle-inverting chain through the pouring mechanism, so that the bottle cap is continuously in contact with the high-temperature juice for a certain period of time to sterilize the bottle cap. At the same time, the cap and the container are heated evenly before entering the spray cooling machine, and the sealing effect of the bottle cap is improved.

The inverted bottle chain conveyor system is mainly composed of two double-body engineering chains that are installed perpendicular to each other and run synchronously, which are the bottle body supporting chain and the bottom support chain. The entire conveying section is divided into three areas: dumping area, sterilization area and supporting standing area. The chain plates are all double-body chains with stainless steel transmission chains at the bottom. The plate surface is flat and the load-bearing capacity is strong. Among them, the bottle body supports The chain adopts a wide chain plate and is equipped with a heat-resistant rubber sleeve, which can better support the bottle body and have anti-rolling and anti-sliding properties when the bottle is dumped, so that the bottle can be transported smoothly.

The spray machine is newly designed by digesting and absorbing similar equipment technology at home and abroad. It is suitable for pasteurizing hot juice bottles in the juice bottling plant.

It adopts a five-stage treatment of hot water preheating, hot water pasteurization, circulating warm water cooling, circulating cooling water cooling, and pure water spraying. The cooling time is based on the user Frequency conversion speed regulation is required.

The equipment is equipped with an automatic metering pump, which can adjust the dosage according to the process requirements or the amount of supplementary water. The hot water is produced by the heat exchanger and flows into the water tank after use for recycling. If the temperature of the spray water does not reach the set temperature, the actuator controls the heat exchanger to heat appropriately. The warm water in the water tank of the sprayer is cooled by the heat exchanger and the cooling tower outside the workshop (cooling tower and circulating pump are provided by the customer) before being recycled. The designed bottle temperature is 85℃, and the bottle temperature is about 40℃.