What Is Bottled Water Production Process Flow Chart
The demand for bottled mineral water is increasing each year. In the Industrial 4.0 era, the packaging of mineral water production lines has been entirely automated and intelligent. Clients may use iBottling's new bottled water packaging technologies to produce high volumes; While having little energy consumption and being environmentally friendly.
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Complete Production Process Flow Chart Of Bottled Water Production As Below
Section 1
Water Treatment
Raw Water Pump
Mechanical Filter
Activated Carbon Filters
Water softener system
Precision filters
Reverse osmosis system
Ozone system
UV light sterilizer
Section 2
Filling & Packaging
Air conveyor
Water bottling machine
Cap feeder machine
Bottle blow dryer
Laser coding machine
Self-adhesive labeler machine
Shrink sleeve label machine
Shrink wrap machine
Pallet wrapping machine
Section 3
Bottle Blowing
Automatic bottle blow molding machine
Semi-automatic blow molding machine
Air compressor
Water chiller
Air dryer
Air filter
Mold temperature controller
Air storage tank
The bottled water production process flow chart is a diagram that illustrates the stages of bottled water production. It includes all the significant steps in producing bottled water, from filtering raw water to bottling the product for sale. The process begins with collecting clean source water and packaging it in plastic bottles or other containers. This blog post will discuss how each step is completed and some challenges that can be faced throughout the process.
The demand for bottled mineral water is increasing each year. In the Industrial 4.0 era, the packaging of mineral water production lines has been entirely automated and intelligent. Clients may use iBottling’s new bottled water packaging technologies to produce high volumes; While having little energy consumption and being environmentally friendly.
We have 26 years of expertise developing and implementing customized whole the flow chart for bottled water production solutions. We reduce manufacturing costs in the blowing process, bottle design, and packaging bottle durability while enhancing bottling quality.
Our advantages
1. Reduced costs with flexible and lightweight packaging solution;
2, High-speed, high-convenience transmission system;
3. High resource consumption rate, low energy emission reduction, and sustainable development;
4. All machines are automated and sophisticated with high-yield capacity to suit your production flow chart for bottled water perfectly .
If you want to have a quick quote for the whole flow chart of the water bottling process, simply contact us by below form
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01.
Water Treatment
1) Raw water pump
The raw water pump provides a pressurization guarantee for the sand, carbon, and fine reverse osmosis pure water equipment filter.
Ensure that the inlet water pressure is stable and sufficient, and play a role in pressurization. The pressurized water pressure is greater than the permeation resistance of the mechanical filter, carbon filter and fine filter. It can efficiently pass through the pretreatment system and provide a sufficient water source for the RO system.
2) Mechanical filter
Description
The mechanical filter with multiple filter layers, also known as a quartz sand filter. Which is mainly used to remove the manganese, iron, heavy metals, silt, rust, colloidal matter, suspended matter and other substances with particles above 20um contained in the raw water. The quartz filter can perform backwashing and forward washing operations.
Function
To ensure the water treatment system’s water output and prolong the service life of the water treatment.
A mechanical filter is generally used in the pretreatment process of water treatment projects, mainly to remove mechanical impurities, colloids, Baidu microorganisms, organic matter and active chlorine.
Features
Mechanical filter cartridge shell materials generally include PE, steel-lined rubber, steel sprayed plastic, steel epoxy anti-corrosion, stainless steel and glass fibre reinforced plastic.
The mechanical filter media generally include quartz sand, activated carbon, manganese sand, anthracite, etc.
According to the water inlet mode, it can be divided into the single-flow filter and double-flow filter. It can be used in combination or alone according to the actual situation.
The single-flow mechanical filter has simple piping and smooth operation.
The filtration flow rate is generally 4-50m/h, and the operation period is 8 hours.
The double-flow mechanical filter has water inlet devices at the upper and lower ends and a water outlet device at the middle.
Application
Mechanical filtration is widely used in water treatment of bottled water production. Mainly used for water treatment and turbidity removal, reverse osmosis, and the pre-pretreatment of ion exchange softening and desalination systems. It can also be used for surface water and groundwater removal.
The turbidity of the inlet water is required to be less than 20 degrees, and the turbidity of the effluent water can reach below 3 degrees.
The double-layer filter material is the upper layer of anthracite 400mm/1.2~2.5mm; the lower layer of quartz sand 800mm/0.5~1.2mm.
3) Activated carbon filters
Description
The activated carbon filter is a more commonly used water treatment filter. The residual chlorine that can’t be removed in the pre-filter can be absorbed by the pretreatment of the desalination system, which will help ensure the equipment’s service life.
Improve the quality of the wastewater, and minimize pollution, particularly by using a post-stage reverse osmosis membrane, ion exchange resin, and other free residual chlorine poisoning.
At the same time, it captures pollutants like organic molecules that have escaped from the preceding stage. It has a significant adsorption and removal effect on peculiar smells, colloids, pigments, and heavy metal ions in the water.
It also has the effect of reducing COD.
The SDI value of RO influent can be further reduced, ensuring SDI<5 and TOC<2.0ppm.
Working principle
The adsorption principle of the activated carbon filter is to form a layer of balanced surface concentration on the surface of its particles. The size of activated carbon particles also affects the adsorption capacity.
Generally speaking, the smaller the activated carbon particles, the larger the filtration area.
Classification
Therefore, powdered activated carbon has a large total area and a good adsorption effect.
However, powdered activated carbon can easily seep into the water tank with water, which is difficult to manage and is rarely utilized.
In contrast, granular activated carbon is difficult to flow owing to particle formation and contaminants such as organic matter in the water are hard to block in the activated carbon filter layer.
Its adsorption capacity is strong, convenient to carry and replace.
The activated carbon filter’s adsorption capacity is directly proportional to the duration of time spent in contact with water. The higher the filtered water quality, the longer the contact time required.
Note
The filtered water should slowly escape from the filter layer. Before using, the new activated carbon should be cleaned; otherwise, black water will flow out.
Before the activated carbon is put into the filter, a sponge of 2 to 3 cm thick should be added on the bottom and top to prevent the penetration of large particles such as algae.
Replacement
After the activated carbon is used for 2 to 3 months, it should be replaced if the filtering effect decreases. New activated carbon and sponge layer should also be replaced regularly.
Function
To ensure the quality of the water generated by water treatment equipment and to extend the equipment’s service life.
4) Water softener system
Working principle
The automatic water softener system adopts the principle of ion exchange to remove calcium, magnesium and other scaled ions in the water.
When the raw water passes through the resin layer in the exchanger, calcium and magnesium ions are replaced with sodium ions, while the sodium ions enter the water. As a result, the water that exits the exchanger is softened without being harmed.
Because calcium and magnesium are the primary components that form scale, cation exchange resins are generally utilized to replace calcium and magnesium in the water (the most significant components that create scale).
With the rise of Ca2+ and Mg2+, however, resin polishing efficiency decreases.
The exchange process
The exchange process of sodium resin represented by RNa is as follows:
2RNa + Ca2+ = R2Ca + 2Na+
2RNa + Mg2+ = R2Mg + 2Na+
After the water passes through the sodium ion exchanger, the Ca+ and Mg+ are replaced with Na+.
Regeneration
When enough calcium and magnesium ions have been absorbed by the resin, it must be regenerated. The regeneration process involves washing the resin layer with saltwater in the saltbox to remove hardness ions from the resin and ejecting the resin from the tank with regeneration waste liquid. Thus the soft exchange function has been restored.
Operation
The operating procedure for the control valve is as follows: running, backwashing, salt absorption, slow washing, salt tank water replenishment, and forward washing.
Structure
Each softening system includes: softening tank, controller (or jet/salt pump), salt tank and salt valve.
Function
Prevent the scale of reverse osmosis and prolong the service life of the reverse osmosis membrane.
5) Precision filters
Description
Precision filters (also called security filters).
The cartridge shell of the precision filters is generally made of stainless steel. The interior uses PP meltblown, wire-fired, folded, titanium filter, activated carbon filter and other tubular filter elements as filter elements.
Choose different filter elements according to various filter media and design processes to meet effluent water quality requirements.
The filter can also choose a quick-installation type to conveniently replace the filter element and clean.
The filter element installed in the precision filters device can be divided into 0.5us, 1us, 5us, 10us, and so on. Different filtering precisions are chosen depending on various situations to guarantee the accuracy of the downstream water and membrane elements’ safety.
Application
The precision filters are widely used in pharmaceutical, chemical, food, beverage, water treatment, brewing, petroleum, printing and dyeing, environmental protection and other industries.
It is ideal for filtration, clarification, and purification of various liquids.
Structure
The precision filters are mainly composed of the filter housing, filter membrane, etc.
The filter housing is primarily consisting of R304 stainless steel. If used on special occasions, such as acid and alkali resistance, R316 stainless steel can be used as the housing.
It can be divided into flange and clamp types, and flange type housing is mainly used on occasions with large filtering flow.
The filter element, which is positioned in the center of the filter housing, is mostly made of PP filter cotton.
In some situations, a wire-wound filter element or an activated carbon filter element can be utilized. The number of deployed filter elements may range from one to dozens, with the size of the processing capacity being the main factor.
6) Reverse osmosis system
Description
The reverse osmosis system is remarkable for pure water filtration and production, which uses the selective permeation principle of the reverse osmosis membrane.
By applying specific pressure to the raw water passing through the reverse osmosis membrane with the high-pressure pump, the water molecules in the raw water can penetrate the membrane and dialysis out.
However, other inorganic salts, microorganisms, and organic substances cannot pass through the membrane due to the retention characteristics of the reverse osmosis membrane, so that pure non-ionized water can be obtained.
Features
Reverse osmosis (RO) is an important part of membrane separation technology, even in the flow chart of the bottled water manufacturing process. Under the action of higher than the osmotic pressure of the solution, other substances cannot pass through the semi-permeable membrane, thus leaving these substances and moisture out.
Because the reverse osmosis membrane pore size is tiny (only about 10A), it can effectively remove dissolved salts, colloids, microorganisms, organic matter, etc., in the water (removal rate as high as 97-98%).
It has good water quality, low energy consumption, no pollution, simple process and easy operation. It has become the most energy-saving and straightforward technology for seawater, brackish water desalination, and pure water production.
At present, it has been widely used in many industries such as medicine, electronics, chemical industry, food, seawater desalination and so on.
Operation
The RO system should adopt an automatic control operation mode according to the water level of the first-level desalinated water tank and the production volume of the reverse osmosis system.
Suppose it is necessary to start, stop or switch the system, it shall be manually switched after confirmation by the operator.
The control of the RO system and the control of the entire chemical water treatment equipment are realized through the control system (PLC) in the control room.
Advantages
According to the raw water quality, ibottling selects imported membrane elements with large water permeability, high desalination rate, good chemical stability, good anti-pollution performance, and good mechanical strength.
iBottling provides the membrane module’s maximum membrane flux, recovery rate, and feed water membrane area for the source water quality and feed water SDI value.
The arrangement and combination of stages and sections of membrane modules are determined by water quality, recovery rate, and water production.
Application
The reverse osmosis system is currently the most advanced and practical desalination equipment at home and abroad. This system uses the reverse osmosis membrane to remove organic matter, bacteria, and viruses.
And the membrane can be operated in an ultra-low pressure working environment to achieve energy-saving and reduce equipment investment and operating costs.
And to achieve the best combination of water permeability and desalination, Dow membrane has been widely used globally, and its technical performance and product quality have won praise from users.
02.
Filling & Packaging
1) Air conveyor system
Description
The Air conveyor system for empty PET bottles uses the wind energy of the fan as the conveying power. It is equipped with a bottle conveying duct with air storage, which realizes that the empty bottles produced from the bottle blowing machine are directly transported to the filling machine or labelling machine for filling or labelling.
Suitable for the transportation of empty bottles in the water and beverage industries.
Structure
PET empty bottle air duct conveying line comprises a fan power unit, straight air duct, turning air duct, up-and-down air duct, dividing and merging device, bottle dropping device and bottle clamping device.
Features
The main structural parts of the air duct are made of 304 stainless steel, which can resist corrosion of various weak acids and weak alkalis.
The air duct bottle blocking strip is made of ultra-high molecular weight polyethylene material, with low friction resistance and high wear resistance. Which ensures long-term service life.
The conveying speed is fast, and the efficiency is high, which can meet the needs of high-speed filling machines;
it does not damage the bottle body;
The conveying line is long, the layout is flexible and diverse, and it can be conveyed horizontally, up and down, and conveyed in a curve, and it can also be conveyed vertically;
Small area, can make full use of plant space, simple structure, high reliability, and convenient maintenance.
Advantage
The electrical system of the whole line is controlled by PLC, man-machine interface, frequency converter and photoelectric sensor.
It can reduce the secondary pollution of empty bottles, save packaging costs and save labour costs.
The system has energy-saving characteristics, compact structure, beautiful appearance, simple control, easy adjustment, easy cleaning, etc.
Which meets the food and packaging industries’ hygiene requirements and is an ideal bottle conveying mechanical equipment.
Application
According to customers ‘ production needs, the air conveying system can be installed with one-layer, two-layer or three-layer cylinders. The cylinder can automatically adapt to the conveying of different bottle diameters. The customer’s choice is simple and convenient, ensuring the efficient and stable operation of the bottle in the air duct. . Mainly used in the customer’s multi-variety product delivery system.
2) Water bottling machine
Description
The PET bottle water filling machine incorporates a bottleneck transmission mechanism to automate washing, filling, capping, and other functions with high precision;
Most of the electrical system parts of the water bottling machine are made of advanced foreign products. And all parts in contact with liquid are made of high-quality stainless steel.
It has wear resistance, stability, and low failure rate characteristics. The product quality is at an advanced level.
The water bottling machine of iBottling is suitable for the filling production of 200-2000ml PET bottled water. The process is fully automated according to the active control of the material water level.
The water bottling machine adopts suspended filling equipment, which can be operated with different bottle types, bottle sizes, and thicknesses, and has a wide range of applications.
Bottle rinsing system
The rinsing mechanism is a rotary rinsing machine that is primarily used for rinsing fresh bottles of beverages, water, and other items. The bottle is then sent to the bottle filling equipment.
The PET bottle enters the water bottling machine by the bottle separating star wheel. The bottleneck is clamped by the clamp and the turning mechanism and turned until the bottle is facing downwards.
After the sterile water is rinsed and drained, it is automatically turned over to the bottleneck facing upwards and conveyed to the filling machine through the star wheel of the bottle.
The main structure of the equipment, the part in contact with the flushing medium and the outer protective cover are all made of high-quality stainless steel, and adopts an open gear transmission.
The new stainless steel clamp has a simple structure and convenient adjustment; the contact area with the bottleneck is small, which effectively avoids secondary pollution to the bottle mouth.
Bottle Filling system
The filling system fills the beverage into the bottle sent by the bottle washer.
The filling valve adopts the pressure filling negative pressure type backflow method. The filling is quick and sensitive, and the filling level is high accuracy.
The cylinder of this type is designed without a spring. The valve’s material does not touch the spring, allowing for easier cleaning of the valve’s interior.
When the filling valve is shut down or has no bottles, the beverage in the valve is at a reflux condition.
To guarantee the tank’s pressure safety, the filling mechanism uses a full tank approach.
Furthermore, the PET bottled water filling machine has a comprehensive CIP cleaning interface.
The double guide rod bottle lifting mechanism is used to ensure that the bottle lifting and centring are steady.
The main drive adopts gear drive, an open combined drive.
It’s a highly efficient, noiseless, long-lasting, easy-to-maintain oil pump.
The frequency converter regulates the speed of the main motor.
And adopt step-less frequency conversion speed regulation.
Screw capping system
The turntable is rotated by the capping machine, which drives it through the reducer. Centrifugal force causes the cap to leave the hopper through the cap outlet.
There is a front and back cap separating device at the exit.
When the back cap passes by, the cap automatically falls into the return pipe, and the back cap is blown into the hopper by the wind.
Cap sorting
The PET bottled water filling machine can only allow front caps to enter the slideway. The cap amount in the hopper is automatically detected by the photoelectric switch to ensure that the lower cap achieves the desired effect.
When the front cap enters the slideway, it may easily fit into the cap feeding tray.
An anti-reverse dial is also built in on the slide to ensure that the cap that goes into the cap plate is correct.
Photoelectric control
A pair of photoelectric switches are also arranged on the slide, and when it detects that there is no cap, the host will be stopped immediately.
Easy to clean
To effectively remove the broken cap without the anti-theft ring and clean the remaining cap of the hopper, there is a movable outlet directly opposite the hopper outlet to meet this function.
3) Cap feeder machine
Description
Cap feeder machine is designed and manufactured according to traditional cap sorting machines’ process and technical requirements.
The capping process is stable and reliable and meets the requirements of automation.
The whole machine adopts 304 stainless steel, and the parts adopt a standardized design and are interchangeable.
The three-screw cap sorting and capping machine is iBottling’s three screw cap sorting and capping machine according to the actual needs of the customer market. It can be directly used with a three-in-one filling machine or a separate three screw cap sealing machine.
The design is mainly based on the characteristics of the three-screw cap itself, having different weights on both sides.
It has the functions of automatic cap feeding, automatic cap arrangement, and automatic cap removal.
Match the work of the production line, save labour and improve the degree of automation.
iBottling can also provide other plastic screw caps, aluminium caps, crown caps and other capping machine equipment, welcoming customers to negotiate and consult.
Working principle
The cap sorting machine uses the principle of the centre of gravity of bottle caps to arrange the caps so that the caps in the same direction (mouth upward or downward) are output smoothly.
Feature
The machine is a mechatronic product with a simple structure.
It is suitable for sorting the caps of products of various specifications.
And according to the specifications and characteristics of the product, the production capacity can be adjusted step-less.
The machine has strong adaptability to caps and can be widely used in various specifications of bottle caps such as food, medicine, cosmetics, etc.
Grouped equipment
This machine can be used with various capping machines and thread sealing machines.
Its working principle is to detect the function of the microswitch. Through the conveying scraper, the bottle caps in the hopper are fed into the cap sorting device at a uniform speed according to the production needs. This ensures that the bottle caps in the cap sorting device can be kept in good condition.
Operate
The machine is easy to operate, with feeding caps at the bottom, and adjustable feeding speed.
When the caps in the hopper is full, the feeding can be automatically stopped.
It is the auxiliary equipment of a capping machine or sealing machine.
Ordinary people can operate and maintain the machine after being instructed.
Standardized electrical components make it simple to get extras and simplify regular maintenance and management.
4) Fully automatic bottle blow dryer
Description
The automatic blow dryer uses the large air volume generated by the blower to forcefully blow off/dry the water droplets outside the bottle to achieve the blow-drying effect.
To prepare for the next step of coding or label sleeving, shrinking, labelling and packaging.
Working principle
The overall structure of the air knife blow dryer is reasonable and straightforward, and the operation is simple.
The drying principle is through the wind instead of high temperature, which is more suitable for some plastic bottles that are not resistant to high temperatures.
Structure
The automatic blow dryer is an ideal choice for small drying equipment.
The air knife dryer comprises 11kw (2 5.5kw) vortex fans, stainless steel and glass frames and air knives.
Double-row small air knives are used.
The air knives can be adjusted up, down, left, and right, fully guarantee the drying effect and strongly apply to bottles of different diameters and heights.
The structure of the whole machine is composed of the frame part, the air knife drying part and the electrical part.
Workflow
After the high-pressure vortex air pump is started, the high-pressure air blown forms a linear high-pressure hot air belt under the action of the air knife.
At the same time, the high-pressure vortex pump generates heat when it is running.
The two effects work together to blow off water drops on the bottle from top to bottom.
To facilitate the processing of coding, labelling, and packaging in the back sections.
5) Laser coding machine
Description
The CO2 laser is a gas laser.
The generated wavelength is 10.6um, which belongs to the mid-infrared band.
The CO2 laser has relatively high power and high electro-optical conversion efficiency.
Working principle
The CO2 laser uses CO2 gas as the working medium to charge CO2 and other auxiliary gases into the discharge tube.
When a high voltage is applied to the electrode, a glow discharge is generated in the discharge tube, and the gas molecules can release laser light.
After the released laser energy is amplified, laser processing can be performed.
Application
It is widely used in marking and cutting clothing leather, buttons, glasses, craft gifts, electronic components, food packaging, plexiglass, fabric cutting, architectural ceramics, PCB, rubber products, shell nameplates, etc.
Applicable materials
Most non-metallic materials include bamboo and wood products, paper, leather, cloth, plexiglass, epoxy resin, fabric, plastic, ceramics, crystal, jade, glass, and artificial stone.
Advantage
Using a fully enclosed imported radiofrequency laser with long life (more than 20,000-30,000 hours) and a stable beam.
Good beam quality, stable light output, low failure rate.
The CO2 series models can also match production lines and automated production lines.
Powerful
Compatible with files of Coreldraw, AutoCAD, Photoshop and other software;
Support PLT, PCX, DXF, BMP, etc.
SHX and TTF fonts can be used directly;
Support automatic encoding, printing serial number, batch number, date, barcode, QR code, automatic number skipping, etc.
6) Self-adhesive labeler machine
Description
The vertical round bottle labeler machine is suitable for round bottle labeling in daily cosmetics, beverages, medicine and other industries.
The automatic labeling machine simultaneously realizes double-sided labeling and circumferential labeling functions.
It can meet single-sided and double-sided labeling of flat bottles, square bottles and special-shaped bottles, and full-circle half-circle labeling of cylindrical objects.
Feature
The product is convenient and straightforward operation, accuracy error, installation adjustment, equipment cleaning, maintenance, etc.
The machine adopts an original pneumatic roller structure with high labelling accuracy.
It is especially suitable for whole-circle labeling of large round bottles, with high repeatability, no bubbles, and unique design.
There is no need for a bottle-separating mechanism, making the system simpler and more efficient.
Due to the high-power servo motor, the application range of the label is enlarged, and the universal problem of insufficient torque of the labelling machine is completely solved.
Advantage
This labeler machine is particularly suitable for high-demand full-circle stickers. The three-roller automatic positioning method can significantly reduce the labelling error caused by unknown factors such as the cone of the product.
One or two labels can be selected for one labelling, which can realize the simultaneous labelling of hand sanitizer, etc.
Advanced and friendly man-machine interface system, online help information, real man-machine interaction, easy to learn, and workers can operate it with a bit of training.
Optional automatic turntable bottle unscrambler can be directly connected to the front-end production line and automatically feed bottles into the labeling machine to increase efficiency.
Optional configuration ribbon coding and labelling machine can print production date and batch number online, reduce bottle packaging procedures, and improve production efficiency.
Application
It is widely used in various industries such as daily chemicals and oil.
The machine design is compact and reasonable, the appearance is beautiful and straightforward, and the filling volume is convenient to adjust.
7) Shrink sleeve label machine
Description
The shrink sleeve label machine adopts the compact body design with the high-performance mechatronics control unit. Also equipped with the humanized and flexible operation interface and the mature servo control system.
Ensure the reliability of the equipment and agile control performance.
Realize high precision, high speed, high stability and smooth shrinkage of the sleeve label.
Simple operation and complete functions.
The conveyor belt, material distribution, product correction mechanism, and sleeve labelling mechanism of the automatic beverage labeller are all driven by separate motors. And it can be step-less frequency-converted to adjust the speed of the sleeve label so that the sleeve label and shrinkage can be complete.
Workflow
The beverage labeller adopts a photoelectric signal sensor.
The PLC processor converts the photoelectric signal to give mechanical instructions to the equipment’s servo motors and driver components. They can coordinate the material tray feeding, the label up and down on the guidepost, and the wheel brush brushing the label down after the label is cut off.
After sensing the label is transmitted on the conveyor belt by the bottle sensor, the PLC processes the signal and issues work instructions within 1 second.
The bottle separating unit, the tray unit, the rack unit, the driving unit, the bottle unit, the brushing unit, the brush unit and other components cooperate to complete the action of sleeving the label or transparent film on the bottle.
Raw material
The main body of the whole machine is made of #304 stainless steel.
It is corrosion-resistant, does not rust, and strictly meets food safety standards.
There is no toxic or harmful substance pollution in the contact part with the sleeve label material.
Components
The beverage labeller adopts a complete set of imported electrical components into the system.
It is processed by Mitsubishi PLC master control, Mitsubishi touch screen soft keyboard operation control, equipped with Japanese Panasonic Optoelectronics, French Schneider servo motor, and French Schneider servo driver.
The equipment and electrical appliances are of excellent quality, stable and reliable.
Flexible bottle sizes
The sleeve labeler machine makes the corresponding centre guide post according to different bottle sizes or bottle and can sizes.
After replacing the guidepost and label film for sleeve labelling, one machine can be compatible with various sizes of bottles.
In the case of a too-large bottle size difference, it is necessary to replace the corresponding centre guidepost and label film.
Also essential to replace the cutter head for label cutting.
The machine height and the front and rear positions of the photoelectric sensors also should be adjusted.
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Classification
There are three types of sleeve labeler machines:
Note
The standard machine is an ordinary photoelectric, which cannot identify the label film with positioning points. Still, the full transparent film fixed-length mode can be used.
Voltage
The sleeve labeler machine has mature technology, but it should pay attention to the grid voltage fluctuation when using it.
If the local voltage is unstable frequently, a voltage stabilizer should be installed at the equipment use site. To prevent the voltage fluctuation from causing damage to the precision parts of the labelling machine.
8) Shrink wrap machine
Description
The shrink wrap machine is mainly used for aquatic packaging products in 350ml, 500ml, 1L, 1.5L and other volumetric bottles.
It is used in conjunction with the constant temperature PE shrinking furnace to make the bottled beverage achieve the packaging effect.
Suitable for shrink films such as PE and PVC.
It is suitable for heat shrink packaging of various bottled products such as purified water, mineral water, soda water, fruit juice drinks, carbonated drinks, cans, glass bottles, etc.
Features
The packaging machine adopts a three-row feeding type, and the feeding can choose single-row, double-row and three-row.
It can automatically wrap, seal, cut, heat shrink, cool, and shape packaged items according to customers’ needs.
Technique
The whole set of equipment introduces German technology and is made by European craftsmanship.
The whole machine is steel and stainless steel, with compact and reasonable structure and remarkable energy-saving effect.
The electrical and pneumatic components adopt well-known foreign brands such as Omron, Schneider, Siemens, Mitsubishi, etc.
After packaging, the bottle bundle has a neat appearance, is compact and not scattered.
Ensure the quality of goods and the needs of long-distance transportation.
Workflow
The beverage enters the multi-row conveyor belt after 90° conversion from the single-row conveyor belt. Then it is divided into 1, 2, 3, 4 rows by the bottle separating board and input by the conveyor belt.
When the front 1, 2, 3, and 4 bottles reach the photoelectric detection, the conveyor belt stops, the limit cylinder goes down, and the pusher cylinder works. The beverage is sent to the sealing and cutting machine for sealing and cutting.
The conveying device sends the beverage to the heat shrinking machine for shrinking and then is sent to the storage shelf by the cooling conveyor belt.
While one bottle bundle is fed into the shrinking machine, the next bottle bundle is automatically aligned.
The pusher cylinder sends the bottle bundle to the sealing and cutting machine for sealing and cutting, and the cycle process is repeated.
Advantage
Film wrapping machines are widely used in the combined packaging of beverages, foods, pharmaceuticals and chemical products.
There is no need for the bottom tray, no carton; a square, round or flat shape can be packaged.
Intuitive effect and low packaging cost.
This machine adopts PLC automatic control.
No shortage of bottles, bottle falling, flexible adjustment and beautiful appearance.
Adjustable hot air circulation structure, suitable for various existing heat-shrinkable films (including colour printing film).
Film replacement is quick and easy, fault warning, complete locking, reliable operation.
To provide a solid guarantee for consistent quality, stable and reliable, long-term continuous production.
9) Pallet wrapping machine
Description
Pallet wrapping machines are developed to meet the packaging requirements of storage, transportation, and loading and unloading operations.
They are categorized into tray-type pallet wrapping machines, top-pressure resistance-stretch pallet wrapping machines, and pre-tension automatic pallet wrapping machines.
The pallet wrapping machine uses LLDPE stretch film as the main packaging material to wrap the goods stacked on the pallet.
It makes the packing material more stable and tidy and can play the role of waterproof and dustproof.
At the same time, the labour intensity is reduced, the labour efficiency is improved, and the damage of the goods in the handling process can be prevented.
It is widely used in food and beverage production, irrigation, paper making, dyes, plastic chemicals, glass ceramics, electro-mechanical castings, etc.
Features
The pallet wrapping machine is controlled by PLC programmable controller.
The number of winding turns can be set, local reinforcement can be selected, automatic reset, etc.
It has protection functions such as overload and overcurrent.
The design is simple, and the maintenance is extremely convenient.
Closed structure, sturdy and durable.
Man-machine interface control
The parameter setting can be completed in the man-machine interface, which is convenient and improves safety performance.
Photoelectric detection function
Sensing automatic photoelectric tracking, sensing the height of the packaged items, and automatically lifting.
Tension adjustment function
Users can adjust the tension of the stretch film at will according to the characteristics of the goods and their own needs to achieve a good packaging effect.
Partially enhanced functions
This function can be realized if the top or bottom of the pallet cargo needs multiple layers of reinforced winding.
Manual/automatic switching at will
The operating mode of the equipment can be changed at will on the man-machine interface, one-key switching.
Automatic protection function
If the machine encounters some unforeseen faults during operation, the preset protection.
The device can play a role in safety protection.
Multifunctional packaging method
PLC control, integrating a variety of packaging methods, can choose the standard according to the needs of the packaging
Quasi-packaging method, single-layer packaging method or enhanced packaging method, etc.
Automatic reset
This machine can automatically restore to the initial state position after each use according to user needs.
Film frame system
The film frame is a dynamic pre-stretching structure. The pre-stretching ratio can reach 250%, which increases the utilization rate of consumables.
The lifting speed of the film frame is variable frequency adjustable speed.
The film frame is a self-developed patented component, light and stable.
Imported wear-resistant rubber roller cloth is selected, with an excellent stretching effect and long service life.
The film system is a follow-up mechanism, AC motor drive, frequency conversion speed regulation.
The lifting column is a chain structure with four sets of rollers running, which is stable and reliable.
Electrical control system
The independent electric control box is located on the column, convenient for maintenance, control and maintenance.
Power switches, AC contactors, buttons, indicator lights, switches, etc., are all made by Schneider, France.
And adopt a uniform specification of wire trough cover. All have wire number identification.
The overall line is neat and clear.
The control switch and button indicator light have apparent signs.
The product’s design, manufacture, and installation conform to the national electrical technology safety standards.
The temperature rise of the whole equipment is in line with the standard rated value of the product during operation.
The switching power supply has good overload protection.
03.
Blowing Line
1) Fully automatic bottle blow molding machine
Description
The automatic bottle blow molding machine is suitable for blowing all kinds of plastic containers and beverage bottles with PET raw material.
It is widely used in blowing various gas-containing beverage bottles, pure mineral water bottles, juice bottles, oil bottles, cosmetic bottles, etc.
Operation
The man-machine interface of the bottle blow molding machine is easy to operate.
The whole machine runs smoothly, there are few failures, and the bottle blowing speed is fast;
The output is high and stable, and the automatic preform loading equipment does not jam the preform, which ensures the stable and efficient product output;
Low energy consumption, high degree of automation and simple operation.
There are no hidden dangers of personal injury, avoiding the threat of semi-automatically taking bottles manually.
Reduce the loss caused by accident and improve the production efficiency;
Technique
The action is stable, and it adopts a double toggle and primary link hinge mechanism with solid clamping force.
With the function of clamping and pressurizing during high-pressure blowing, the action is stable and reliable;
It can store the blowing process parameters of a variety of different bottles.
Changing different moulds and preforms can be directly retrieved from the computer without re-adjusting the data.
It has the kinetic energy of automatic alarm, automatic fault detection and judgment.
Structure
The structure of the automatic bottle blowing machine is simple, and the main body of the oven is integrated with a slideway, which is convenient for maintenance;
Unique lamp installation method, suitable for preforms of different structures;
The infrared lamp tube is used for heating, and the penetrating power is strong, and the heating is even.
The width and height of the reflector can be adjusted, which can be suitable for heating preforms of different structures;
Air circuit design is professional; air circuit design for action and blowing is divided into two parts.
To meet the needs of different air pressures for blowing bottles and actions; to achieve high-pressure blowing bottles.
A high-pressure blowing exhaust recovery system can also be optional to purchase, which can save 10-15% of the gas source;
Components
The detection components are selected from well-known brand products, and the solid current control is selected from imported famous products.
Reliable performance, accurate response, long service life;
Preform feeder system of automatic bottle blow molding machine
The conveyor belt lifts and conveys the preforms from the hopper to the complete linear slider,
The preforms are automatically arranged in sequence through the preform sorting slider.
The feed-in clamping claw fetches the preform onto the revolving slider.
The compacting device ensures reliable preform loading and reduces downtime caused by preform jams.
The heating system of the automatic bottle blow molding machine
Good ventilation and cooling system can fully ensure the heating of the preform and the stable cooling of the bottleneck.
PLC separates the temperature control independently, the drying tunnel design is reasonable, it can be turned over, and the front and back up and down are reliable.
The heating centre distance of the preform is small.
The heating speed is fast, and the energy-saving is 40% compared with the ordinary heating system.
The bottle preform enters the oven with the bottleneck upward.
Thanks to the efficient oven cooling and ventilation system, the bottleneck and shaft will not be overheated.
Even thick preforms and high-productivity products can be cooled well on the preform surface to avoid crystallization.
To ensure the yield of the bottle blowing, the oven of the bottle blowing machine is essential.
The oven structure of this machine adopts the current international advanced infrared radiation heating energy-saving technology.
The temperature control adopts automatic negative feedback, closed-loop adjustment mode.
The mould clamping mechanism of the automatic bottle blow molding machine
The mould clamping mechanism adopts a five-point double-crank mould clamping mechanism.
Optimized design, large clamping force and fast speed.
The revolving slider is driven by a servo to quickly send the heated preform to the mould for blow moulding.
After heating, the preform leaves the oven and is transferred to the blowing mould via a servo motor.
The integral air valve is used for pre-blowing, blowing and taking out.
Therefore, it is necessary to ensure that it is fast and accurate.
Repeated adjustments of blowing equipment should consider the flexibility of blowing processing.
The mould change of the bottle blowing machine is quick and easy.
A slideway for the upper mould is specially set in the lower part of the template.
Just put the mould on the slide and slide it gently.
It saves time and effort, and at the same time, avoids the situation where workers are easily injured when changing moulds.
The bottle outlet device is connected with the air conveying chute to directly transport the formed bottles to the bottle filling machine.
2）Semi-automatic blow molder
Description
The semi-automatic bottle blowing machine is controlled by a microcomputer, which can more accurately control the technical parameters of the bottle blowing.
The operation is safe and straightforward, only one person is required, and no special training is required.
The semi-automatic bottle blowing machine can blow carbonated beverage bottles, mineral water bottles, cosmetic bottles, hot-filled bottles, especially oil bottles with handles.
Bottle blowing device
The blowing device is controlled by the PLC control system.
The whole process is completed by one touch, and the control accuracy reaches 0.01 second.
Pneumatic system
The power system provides power for the movement of the machine,
including the driving of the machine and the blowing action.
The blow molder is equipped with world-famous brand parts such as FESTO.
Reduce noise, save energy, and ensure the high quality of PET bottles.
Clamping system
The iBottling semi-automatic bottle blowing machine adopts a three-platen clamping system.
Provides a strong clamping force to meet the needs of blowing air pressure up to 35 Pa.
It is equipped with an adjustment device to adjust the distance between the front and middle templates.
Also, the position of the stretching cylinder for different moulds.
Auxiliary equipment
The iBottling semi-automatic blow molder has many auxiliary devices,
Like a storage cylinder, the air pressure is stable.
The lubrication device reduces the loss of various parts of the machine.
The multiple air intake device satisfies the single-inlet mode of high-pressure compressed air and the dual-inlet mode of high pressure and low-pressure air.
Safety device
There are two start switches on both sides of the machine to ensure the operator safety.
These two switches can only start the machine when they are pressed simultaneously.
In addition, there is an emergency stop switch, which can stop the machine in case of an emergency fault.
Heating capacity
The iBottling series preform heating system adopts infrared tube heating.
The powerful heat radiation ability of infrared can quickly heat the preform to the required temperature. The super penetrating power makes the inside and surface of the preform continue to be heated evenly.
Cooling device
The iBottling series preform heaters are equipped with air cooling and water cooling devices.
Used to cool the heated preform bracket to ensure that the neck is not deformed.
The exhaust system on the heater ensures the stability of the temperature in heating.
Heating control system
The iBottling series preform heater adopts an independent heating control device.
Different preforms can get an ideal heating effect in each heating zone.
Each heating lamp has a voltage regulator to control the voltage of each heating lamp.
The voltage value can be monitored and adjusted simply and conveniently through the LED display.
Adjusting device
Multiple adjustment devices are installed on the preform heater to enhance the machine’s performance.
This device can adjust the width and height of the drying tunnel according to different bottleneck sizes and heights.
The size of the exhaust port can also be adjusted according to different needs.
Assisting equipment
The iBottling semi-automatic bottle blowing machine preform heater is equipped with a series of auxiliary equipment.
Such as cooling water supply system, movable base plate for easy machine movement, air inlet, etc.
These devices make the operation of the machine simple and convenient for customers.
3) Air compressor
Description
The PET air compressor is the main body of the air source device of the blow molder.
It is a device that converts a motor’s mechanical energy into gas pressure energy. And it is a unique air pressure generating device for the bottle blowing machine.
Classification
Blowing air compressors are mainly used in the supporting industries of iBottling blow molder.
Blowing air compressors can be divided into low-pressure blow molding machine (15-25bar), medium pressure blow molding machine (25-35bar), high-pressure blow molding machine (35-40bar) according to air pressure.
According to their working principles, blowing air compressors can be divided into piston compressors, screw compressors, and centrifugal compressors.
The principle of operation for a positive displacement compressor is to compress the gas volume in order to boost gas molecule density per unit volume, resulting in higher compressed air pressure.
The working principle of a screw compressor is twin screw compression.
The kinetic energy of the gas in the cavity of the twin-screw compressor is converted into pressure energy, increasing the compressed air pressure.
The centrifugal compressor uses the high-speed rotation of the impeller to convert the gas into kinetic energy under the high-speed centrifugal condition, thereby providing the compressed air pressure.
Choose model
First, select the type of air compressor according to the characteristics of the air compressor.
According to the working pressure and flow parameters, the output pressure PC and the suction flow QC of the air compressor are determined. The air compressor model is finally selected.
The choice of air compressor is mainly based on the pneumatic system’s working pressure and flow rate.
The working pressure of the gas source should be about 20% higher than the highest working pressure in the pneumatic system.
Because the loss along the way and the local loss of the gas supply pipeline should be considered.
If the working pressure requirement in some parts of the system is low, a pressure reducing valve can supply air.
The rated discharge pressure of the air compressor is divided into
Which can be selected according to actual needs.
Low-pressure air compressor
The commonly used low-pressure air compressors in the auxiliary equipment of the blow molding machine are mainly piston-type low-pressure air compressors and screw-type low-pressure air compressors.
Use the free gas as a piston to compress the gas and then expel the gas.
The screw compressor is a rotary positive displacement compressor in which two rotors with helical gears mesh to compress and discharge gas.
Compared with the piston-type low-pressure air compressor, the screw-type operation is stable and safe, energy-saving, and automatic and adjustable. All iBottling blow molding machines use low-pressure screw air compressors.
Function: Carry out pre-blowing and low-pressure blowing. Complete the blowing with high pressure to ensure a one-time bottle formation rate.
High-pressure air compressor
It comprises a compressor host (excluding gas storage tank), motor, inter-stage cooler, air separation and purification device, etc.
The gas inhaled in the tank is compressed into three levels and then separated and filtered to purify the high-pressure air without odour.
Function: Compress the air in the free state into a clean and odourless high-pressure gas, blow the preform at high speed, and form a bottle at one time.
4) Bottle blowing machine water chiller
Description
Blow mold water chiller is used in blow molding machines, hollow moulding machines, injection blow molding machines, and plastic processing machinery mould cooling.
It can effectively improve the surface finish of plastic products and reduce the surface marks and internal stress of plastic products.
The product does not shrink or deform, reduces defective products.
Suitable for demoulding plastic products accelerates product shaping. Shortens the injection moulding cycle and significantly improves the production efficiency of the bottle blowing machine.
Structure
The protection system of the blow molding machine water chiller includes:
Ensure the regular operation of the unit.
The features of water-cooled water chillers are
Ergonomic panel, fully automated control.
Equipped with a precision electric temperature controller, which can run smoothly for a long time;
The use of high-efficiency heat transfer heat exchangers has a low cooling loss, easy to return oil, and the heat transfer tube will not freeze and crack;
imported high-performance compressors, high EER value, low noise, and stable operation.
The feature of air-cooled chillers are:
No need to install a cooling tower, easy to install.
Easy to move, suitable for occasions where there is a lack of water source without water tower installation;
Low noise fan motor, excellent cooling and condensation effect.
Stable throttling structure, excellent anti-rust treatment;
Imported high-performance compressor, high EER value, low noise, regular operation.
5) Blowing machine air dryer
Description
The air dryer is a kind of equipment that uses the working principle of cooling and condensation to dry compressed air.
The refrigeration dryer adopts the working principle of cooling and condensation. It is mainly composed of three parts: a heat exchange system, a refrigeration system and an electrical control system.
Workflow
The compressed air first enters the pre-cooler for air-air or air-water heat exchange, removing part of the heat energy.
And then enters the cold and hot air exchanger. Exchanges heat with the cold air cooled to the pressure dew point from the evaporator. The temperature of the compressed air is further reduced.
After that, the compressed air enters the evaporator to exchange heat with the refrigerant. The compressed air temperature drops to 0-8°C.
The water in the air will precipitate at this temperature; after being separated by a gas-water separator, it will be discharged through an automatic drain.
The dry low-temperature air enters the cold and hot air exchanger for heat exchange, and is output after the temperature rises.
Control
An optional microcomputer control system, with import and export temperature display, dew point temperature display, pressure display, fault alarm and other functions. And it can realize centralized computer control online.
Components
The refrigeration compressor is selected from the United States TECUMSEH, BRISTOL, France MANEURCP and other world products, with stable operation, low noise, power-saving and long service life.
Advantage
The pre-cooler adopts newly developed internal and external multi-fin exchange tubes.
The efficiency is increased by more than 3 times.
And the power consumption can be saved by more than 60%
The large evaporator design is suitable for various climates to ensure a stable dew point.
The gas-water separator adopts a double separation design to separate and remove the condensed water.
6) Air filter of bottle blowing machine
Description
The function of the air filter is to separate the liquid water and liquid oil droplets in the compressed air, and filter out the dust and solid impurities in the air. Still, it cannot remove the gaseous water and oil.
Workflow
The air generally contains harmful substances such as dust, rust, and moisture.
The compressed air in the first filter device will have a coalescence effect, condensing some particles and staying on the filter.
These tiny particles will become larger water droplets after a long time of condensation.
Compressed air will enter the separation chamber, and its flow rate will naturally slow down.
The particles passing through the previous channel will gather again and condense on the water trap.
The non-condensed water is water with impurities and will flow along the bottom of the device.
As soon as it reaches the location of the drainage equipment, the electric drain gate will discharge the water.
After filtering, you will get dust-free, oil-free, and water-free, relatively dry, clean compressed air.
Clean air can effectively extend the service life of pneumatic equipment.
7) Mold temperature controller
Description
Blow molding machine temperature controller is used in the plastic bottle industry to control the mold temperature.
The control of mold temperature directly affects the appearance of bottles.
The mold is always maintained at a constant temperature to ensure the product bottle mouth is smooth.
Prevent defects such as lack of glue, deformation, bubbles, and imprints, and ensure even thickness of the bottle wall.
Improve production efficiency, improve product quality and appearance and surface finish.
The temperature rises and falls fast, and the temperature control is accurate and stable.
It is one of the necessary auxiliary equipment in the plastic bottle industry.
Features
Use customized horizontal high-temperature resistant pump, stable flow and reliable performance;
Stainless steel pipelines and fuel tanks will not rust due to long-term use, blocking the pipeline and affecting the pump’s service life.
Visualized heat transfer oil level tube, easy to check the stock of thermal media, remind users to replenish heat transfer oil in time;
Components
Adopt well-known brand components such as Omron, Fuji, LG, Schneider, etc.;
Imported heating components ensure excellent performance and longer service life of the mold temperature controller;
Operation
Instant cooling function can quickly shut down after the end of production, saving operation time;
Equipped with a liquid level alarm, when the heat medium is lacking, the mold temperature machine will automatically stop heating and stop the operation of the pump to give an alarm;
The circulating medium temperature is automatically controlled, and the temperature control accuracy is ±1℃;
8) Air storage tank of bottle blow molding machine
Description
Air compressor storage tank, also known as a compressed air storage tank.
It is a pressure vessel specially used to store compressed air.
The function is used for air storage and buffering.
To avoid the frequent start of air compressors and allow compressed air to settle in the air storage tank.
Which is more conducive to water removal and pollution removal.
It is mainly used in conjunction with air compressors, refrigerated dryers, filters and other equipment to form the power source for the industrial production-compressed air station.
Advantage:
1. The amount of stored gas, on the one hand, solves the contradiction in the amount of gas that may occur in the system in a short time.
On the other hand, it can be used temporarily when the air compressor fails or other emergencies (such as power failure);
2. Eliminate or weaken the pulsation of the output airflow of the piston air compressor.
Stabilize the air source pressure to ensure continuous and stable output airflow;
3. Provide a more extensive system capacity.
Extend the “start-stop” or “load-unload” cycle period of the air compressor.
Reduce the switching frequency of electrical equipment and valves.
4. Further cooling the air, separating and removing impurities such as moisture and oil from the compressed air.
Reduce the workload of other processing equipment downstream of the pipe network.
Make all kinds of gas equipment obtain the required high-quality gas source.
04.
Conclusion
The process of bottled water production is a long, complicated journey. If you’re looking for an easy-to-understand overview of how it all happens, this production flow chart for bottled water should do the trick. As in most industries with large machinery and processes that are hard to understand, there are experts ready to answer your questions or provide quotes if you need help along the way. Get in touch with us today by the below form to learn more about what we can offer for your bottled water filling needs!
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Polyester & Product Stewardship Consultant
11moVery informative.