WATER BOTTLING LINE 12000BPH

Description

SCOPE OF PRODUCTION
PET Still Water filling Line 12000BPH (500ml)

PET Still filling Line Complete
(Spring Water) Ozone and Filtration Spec for Natural Water)

350ml x 15000 BPH,
500ml x 12000 BPH,
750ml x 10000 UPH,
1500ml x 7000 UPH

Commercial Offer:

Bottle Blowing Machine                                                                   

1. Blow molding machine, 6 cavity

Description:

R series linear full-electric PET bottle blow molding machine is a high-speed automatic PET blower designed and developed with the most advanced bottle blowing technology at present, the advantages of which can be described as speedy, stable, simple, general purposed and environmental safety. It is mainly applicable to blow molding PET containers for water, beverage, juice, etc. The machine yields abundantly with high efficiency. The capacity of each cavity has been increased to 2600~2000bph when the bottle size is equal to or less than 0.55L respectively, which can meet the high-end customer’s requirements. Equipped with a preform auto-loading system, the machine works fully automatically with consistent performance and high speed, without an operator’s interference during the whole process. Accordingly, the chance of contamination can be reduced manifestly, which assures the quality of products.

Features:

The innovation of mold locking system

Servo Motor is adopted to drive the movement of the 4-piece mold holder and the high-pressure supercharged mold locking mechanism is equipped. This mold clamping and opening mechanism have been developed successfully by ourselves upon dozens of years’ practice which is now the most efficient clamping and opening mechanism applied on the domestic linear blow molding machines. The mold movement cycle time is only 0.3~0.5 seconds. Meanwhile, the whole movement is accurate, stable and speedy while the impact between the mold plates have been amortized, which can effectively protect the molds and reduce the visibility of parting lines on the finished bottles.

Application of the motion controller system

Using Omron motion controller system (integration module type), using the PTO (servo positioning module) system for high-speed positioning, looking for track the target location, proximity sensor switch to the servo system is a high-speed signal, by servo motor built-in high inside track the location of the precision rotary encoder online detection, information feedback to the control system, and finally by the positioning module in high-speed positioning work.

Application of the servo motor

The mold movement mechanism: the servo motor reducer synchronical transmission system is adopted to fulfill the reciprocating up and down motion of the two hinge mechanisms on both sides of the mold hauled by two linkage rods respectively. In this way, the two mold holding plates in the middle move oppositely or towards each other, which is generally known as mold opening and closing. The hauling wheel driven by the servo motor makes clockwise rounds continuously. Each round leads to a complete cycle of mold holding plates movement——open and close. Also, the high-pressure air supercharged mold locking mechanism is applied which buffs the impact between mold plates and effectively protects molds. Besides, it does help to reduce the visibility of parting lines on finished bottles. The servo motor driven mold movement mechanism is designed and created upon rigid engineering simulation analysis, which ensures that the series of the mold motions are simple, accurate, consistent and speedy, making cycle time 0.2~0.4 seconds.

The stepping and heating mechanism: Servo motor is driven stepping motion for preform rotary heating system, the preform heating stepping is controlled by variable frequency motor, preforms (preform neck is upwards) are 360 degrees uninterruptedly rotary heating,38mm Preform heating pitch, more preforms are uninterruptedly heated within the same distance, which improves the efficiency and energy saving above 50%.Servo motor driven the steeping motion makes it much speedy and stably, shorten the production cycle time, greatly improve production efficiency. The preform transfer system with the grippers and variable pitch system are both driven by the servo motors to ensure high speed and accurately perform handling between the two mechanisms.

The perform variable pitch system: This mechanism has adopted the screw to change the cavity pitch from 38mm to 105mm driven by the servo motors, to ensure high speed and accurately perform handling between the two mechanisms.

Preform transfer system with the grippers and bottle outfeed mechanism: Heated preforms delivering into the blow mold and the finished bottles out-feed driven by the same servo motor and the synchronous belt, to ensure the high speed and accuracy for these two motions.

The stretching mechanism (down stretching): the stretching rods are driven by a servo motor all at once, which ensures the synchronicity of the motion of the rods and makes it easier to do adjustment prior to production.

(After interchanging the blow mold, makes it much easier to adjust the height of stretching rods, just need to input the data on the touch screen, instead of doing the adjustment by manual.)

Energy-efficient heating system

The paratactic collocation of the preform heater shortens the heating pitch between preforms, making good use of the heater’s space and energy efficiently, which decreases the energy consumption and the area for installing the machine. Each lamp pipe in the heater can be controlled individually. Moreover, the heaters are equipped with a controlled circulating air cooling system that can keep the temperature constant inside the heater and preforms heated consistently, which makes high good part rate. Additionally, the homo-thermal heater works excellently in the condition where the temperature fluctuates greatly(10℃~30℃). The positioning of the heating stepping system is conducted by the servo motor, swift and stable. The machine is equipped with the preform temperature detection at the last heaters if the preform temperature does not reach the blowing temperature, the preforms going into the blow mold but no blowing, saving the air.

Performance and Advantages:

• • The man-machine interface is easy to operate. Everything is computerized, including temperature adjustment and preform distribution.
  • • Preform unscrambling, loading, bottle handling, and order are all operated by stainless steel manipulator automatically without second contamination.
    • The circulating chilling water system, as well as the fan with converter controlled, can protect the bottleneck against deformation when the preform is being heated.
    • The homo-thermal heater adopts auto reflection and closed-loop adjusting system which has the power supplied constantly in proportion, not affected by the fluctuation of voltage. The conveying chain is short-pitched and paratactic, which helps to realize slow heating and low power consumption. As a result, the preform can be heated evenly and easy to blow.
    • The positioned installation of molds makes it possible to change molds easily within one hour.
    • All the critical parts we use for the machines, such as the electrical, pneumatic components, servo motor, etc, are famous branded parts imported from Japan, USA and Europe，which ensures the stability and long life of our equipment.
    • Easy Maintenance

    Since the machine is connected to the programmable logic controller (PLC) via particular communicating cables, the user can manage all the actions of the machine through the PLC, which will send warning signals and the problem diagnosis report to the operators when there is something wrong with the machine. Accordingly, the operators can easily find out the causes that lead to the problems through the indications shown and fix them quickly.

    • Safety

    R series is equipped with following mechanic and electric protecting devices in order to assure the safety of operators and durable stable operation of the machine.

    • The safety of operators

    The machine is totally enclosed with a perfect reliable safety door and also equipped with an aluminum antislip plate on the principal surface, which can assure operators’ safety to the largest degree.

    • The safety of the machine

    The multiple points detection technique is adopted to ensure the safe running of the positioning system, the clamping system, and the stretching system to the largest degree.

    Technical parameters:

    Model	PL-CS6-38
    Blowing part	Mold clamping force	60000 Kg
    	Side mols stroke	130 mm
    	Blowing rod stroke	320 mm
    	Bottom mold stroke	50 mm
    	Bottles’ distance	120 mm
    	Cavity	6 cavities
    Bottle specification	Bottle max volume	1.5 L
    	Bottle mouth size	18-30 mm
    	Max body diameter	105 mm
    	Max body height	320 mm
    	Preform	3 mm
    Actual capacity		12000 BPH (500ml)
    Power consumption	Heating oven	4 pieces
    	Heating tubes	36 pieces
    	Nominal power consumption	50 kW
    	Actual power consumption	25-35 kW
    High pressure air compressor	Blowing pressure	35-45 Kg
    	Compressed air consumption	10 m³/min
    Chilling water	Operating pressure	Over 4 Kg/cm²
    	Temperature range	5-20 ℃
    	Cooling capacity	21000 kcal/hour
    	Cooling water flow	70 m³/hour
    Machine specification	Dimension	5530*1750*2600 mm
    	Weight	8000 Kg

    Electric components

    Items	Supplier, Origin
    PLC	HTC, Taiwan
    HMI	BeckHoff, Germany
    Servo motors (Servo motor driven the stretching system, the stepping system, the mold clamping system, the preform transfer system, the variable pitch system)	Delta, Taiwan
    Speed reducer	Siemens, Germany
    High pressure blowing valve (With compressed air recycling system)	Parker, USA
    Pneumatic components	FESTO, Germany
    Control button, intermediate relay	Schneider, France
    Contactor, thermo relay	Schneider, France
    Silicon controlled rectifier	Semikron, Germany
    Infrared tungsten tube	Lianggu, China
    VFD	Taian, Taiwan

    1.1 Air chilling machine

    

Description:

After the SIC-A series chiller is turned on, the compressor 1 starts to work, turning the refrigerant into a high-temperature compressed gas. The gas circulates in the direction to BC, enters the condenser 3 and exchanges heat with the air, and changes from a gaseous state to a liquid state. while the heat is taken away by the air.

In the CDEF process, the liquid condensing agent coming out of the condenser passes through the liquid storage device 4, passes through the drying filter 5, get dried and filtered, passes through the liquid pipe solenoid valve 6, and the liquid crystal mirror 7 then  reaches the expansion valve 8.

During the FG process, the high-pressure liquid refrigerant is throttled and depressurized by the thermal expansion valve, and the temperature is lowered.

During the GA process, the low-temperature & low-pressure refrigerant exchanges heat with the chilled water through the evaporator 9 to cool the chilled water to the preset temperature; the low-temperature gas refrigerant that comes out after the evaporator returns to the compressor, and finishes the recycle.

Technical parameters:

Component list:

 1.2. High pressure air compressor

Technical parameters:

 2.1 Compressed air cooling drying filtering system

Technical parameters:

Filling & Post-Packaging Machine                                                         

1. Washing-filling-capping Tri-block

Features:

• Welded with SUS304, the product contact surface is SUS304 food-grade (SUS316 optional).
• High-efficiency rinsing nozzles can spray water to any part inside the bottle.
• Corrosion-resistant bearings from NSK or SKF are used.
• Multiple filling options are available: mechanical valve filling, flow meter filling, weighing filling, or laser positioning filling.
• The gear transmission system has an open design.
• The bottle transporting system is designed to hold the neck securely.
• Equipped with VFD control for increased energy efficiency.
• Features a PLC control system.
• All electrical components are supplied by world-renowned companies.
• Utilizes French “ZALKIN” capping technology for enhanced performance.
• Capping torque can be adjusted as needed.
• Cap absence can be detected, and upside-down caps can be sorted out.
• An online cap sterilizer option is available.

Technical parameters:

 Component list:

 Detailed description

1. Rinsing part:

Features:

• Rotating design suitable for rinsing containers used in alcohol, beverage, pure, and mineral water applications.
• Neck-holding catchers invert bottles, allowing rinsing with aseptic water.
• Primary structure, as well as contact parts with aseptic water and the cover, are constructed from stainless steel.
• Bottle sensor installed to prevent the introduction of improperly positioned bottles.
• Water inlet pipe equipped with a pressure gauge and valve stabilizer.
• Adjustable height to accommodate bottles of different sizes, with maximum and minimum height protection.
• Optional aseptic water recycling system.
• Automatic cessation of rinsing in the absence of bottles, restarting upon detection of bottle presence.

 2 .Filling part

Features:

• Designed and manufactured based on German technology.
• Utilizes an isobaric mechanical filling valve for precise filling.
• Neck-holding design ensures seamless contact between the bottle mouth and the filling valve.
• Equipped with a bottle-explosion-proof device; the filling valve can automatically shut off.
• Adjustable filler height to accommodate bottles of different heights, with maximum and minimum height protection.
• Open-style gear transmission for high efficiency, low noise, long service life, and easy maintenance.
• Motor adjusted by the inverter, allowing for stepless frequency conversion speed regulation.
• Bottle transporting system features a simple structure and short changeover time to accommodate different bottles. Uses a bottom-holding method for transportation.
• PLC system controlled, displaying errors on the screen, such as bottle jams or cap absence.
• Adheres to a “no bottle, no fill” principle.
• Liquid level inside the filling tank is monitored by a sensor, ensuring stable filling.
• Key electric components sourced from world-famous companies.
• Sealing rings on the filler are manufactured in Europe.

 3.Capping Part

Features:

• Caps are unscrambled in the silo, and the quantity is actively monitored.
• Adjustable capping torque to meet specific requirements.
• Flip-over adjuster installed on the slide to prevent the insertion of upside-down caps.
• Two photoelectric sensors on the slide provide cap-absence alarms.
• The capper can adjust its height to accommodate bottles of varying heights, with both maximum and minimum height protection.

2.1 Cap hopper

Features:

• • Gentle handling to prevent any damage to plastic caps.
  • Transparent PC board facilitates efficient cap sorting.
  • Equipped with an AC motor and speed reducer for reliable performance.
  • Includes an indicator light to signal cap absence.
  • Automatically identifies and removes upside-down caps, redirecting them to the hopper for reuse.

Technical parameters:

 2.2. Cap online sterilizer

Features:

• Utilizes a highly efficient centrifugal cap-unscrambling method with low wear.
• Cap detecting system provides signals to control the cap lifter.
• Special design on the cap unscrambler’s guide rail prevents the passage of upside-down caps.
• Caps undergo a comprehensive cleaning process, including spraying with disinfecting solution, rinsing with aseptic water, and drying with aseptic compressed air.
• Disinfecting solution tank features maximum and minimum liquid levels, allowing for convenient replenishment.

Technical parameters:

 3. Bottle drying machine

Description:

• The blower adopts a fan as the air source.
• An air knife type structure, and the size of the sealing can be adjusted.
• The top side and the two vertical sides of bottles can be blown to dry thoroughly.
• Easy for labeling, printing, packing operations.

Technical parameters:

 4. OPP labeling machine

Technical parameters:

 Component list:

5. Laser printer

Features:

The printer is simple to use and the operator can focus on production:

• Touchscreen user interface with built-in tools and wizards to guide you through code creation, job setup and conversion to reduce operator error.
• Oversized logo area supports accurate coding in multiple locations to identify more content in larger areas.
• Printing speeds up to 500 characters/second.
• Maximum line speed of 60 m/min (197 ft/min).

Increased productivity and reduced costs with uptime advantages:

• The portable lightweight 3030 enables simple conversion. By adjusting the 3030’s mobile rack, it takes less than 20 minutes to set up for different sized products.
• Durable laser tubes can be used reliably for many years.

Provide consistent high quality coding for a variety of simple applications:

• Lined technology for dynamic marking and static marking for clear, high quality marking.
• Internal laser cooling system based on high-efficiency laser design saves money without external air supply.
• The 3030’s compact, stand-alone design integrates well into existing production lines and accommodates a wide range of placement angles and heights.

Technical parameters:

6. Automatic PE film shrink wrapping machine

Features:

• Classic shape, novel structure, unique, easy operation, and maintenance. The use of pneumatic expansion support film roll, electronic sensor film delivery ensures stable and fast film feeding, making membrane application convenient.
• The unique threat shaking bottle feature ensures smooth product separation, preventing bottle squeezing.
• The feeding conveyor and host length are 1.6 meters longer than those of other companies. This length is conducive to bottle sorting, effectively increasing the number of membrane rods, reducing the transmission line speed, and enhancing equipment performance tolerance.
• The shrink chamber employs a unique circular air supply technology for multi-directional air flow control. It features adjustable wind speed and outlet position, significantly improving the shrinking effect.
• The shrinkage chamber adopts a newly developed open structure outside, facilitating maintenance. It incorporates a thick insulation layer for energy-saving and high-temperature control accuracy.
• Man-machine interface: B&R LCD color screen with a user-friendly interface for fast parameter setting.
• Electrical Configuration: Over 90% of the entire electrical components are imported high-quality brands. With 10 years of optimal configuration, the machine is stable and reliable.
• The machine incorporates energy-saving technology design, resulting in a 30% reduction in power loss. It promotes a low-carbon, environmentally friendly operation.

Technical parameters:

Component list:

11. Cartoning Machine

The carton forming process is completed in three steps:

1. When the suction mechanism pulls down the cardboard, a set of forming baffles folds the cardboard into a box shape, completing the initial folding of the cardboard.
2. The front box-pressing cylinder baffle presses down, using a cam mechanism to achieve the front folding and pressing of the cardboard. The forward and backward movement of the baffle compresses the front edges of the carton.
3. The fixed gluing guns on three sides will spray hot melt gule onto the carton cases.
4. The rear box-pressing device fixes and positions the carton while the side pressing cylinders on both sides push the side pressing plates, completing the carton forming process.

Description:

The machine uses servo-enhanced positioning, PLC controlling, multi-degree rotation via chain, chain wheel speed regulator. It features highly automatic, reliable controlling, easy to adjust, intelligent operation, can be widely used for beverage, beer, chemistry, food, medicine industry, can pack all kinds of cans and bottles in the second time package, can match with auto filling production line.

Bottles/Cans are separated to multi-channels at conveyor, and then grouped by bottle separating system evenly, then the bottles/cans drop onto the cardboard via bottle dropping system. Within the dropping process, card boards are folded to be cartons by the carton folding system. Through main drive, carton move forward, at the same time, The glue is being sprayed onto the carton, again the second stage carton forming system completes the processing of the carton forming with the help of the glue applying system. and through the side pressure and carton press system the carton is firmly conglutinated.

Description of the bottle reversing system:

The bottles are fed into the system one by one, and we arrange them into 4×6 configurations. During the sorting process, the bottles are pre-arranged into 4×6 groups, with each sorting cycle handling approximately three to four boxes. These boxed bottles queue at the waiting station until four boxes are accumulated, then they move on to the next step.

When the boxed bottles enter the next workstation, each package of bottles is processed individually. First, each package undergoes orientation adjustment, and the 24 packages in the 4×6 configuration are transported to the turning device. In the turning device, the packages are rotated 90 degrees using a two-dimensional reducer and a servo system. After the rotation is completed, the packages continue forward and are finally pushed to the wrapping station by the servo system for packaging operations.

Technical parameters:

Component list:

7. Air conveyor

The air conveyor is mounted on supporting legs, which are in direct contact with the ground. Fans are positioned on the air conveying duct, with each fan’s air inlet equipped with an air filter to prevent dust from entering the containers. Bottles are suspended on the air conveyor by their necks and transported to the rotary filler using air.

An automatic drop-off device is integrated into the air conveyor, driven by a cylinder mechanism. In the event of a temporary shutdown or deceleration of the downstream machine, the bottle-dropper can be shut down manually when a certain number of empty bottles accumulate on the air conveyor. After manually collecting and putting the bottles back on the air conveyor, this ensures that the blow molding machine does not need to be turned off in such instances.

Multiple sets of photoelectric switches are positioned on the air conveyor. The photoelectric switch near the air crossroads controls the direction of the air blowing, while the other switches are dedicated to managing the automatic drop-off device, ensuring the smooth operation of the entire air conveyor.

• The main body is constructed from Stainless Steel 304.
• Fan blowers feature built-in air filters, preventing secondary pollution.
• The air inlet of the fan outside the sterile room is equipped with a primary air filter to prevent dust from entering the room.

Technical parameters:

6. Belt conveyor & Buffering system

Description:

The operational efficiency of a production line is significantly influenced by the configuration of the conveyor line. This configuration must consider the occasional short-term shutdown of rear-end equipment, such as for label replacement, ensuring that the shutdown does not impact the operation of the front-end equipment. It should also facilitate seamless connection between the front and rear equipment to achieve high overall production line efficiency. Our production line layout is meticulously designed, taking into account the balance between customer investment and production line efficiency. Leveraging advanced global technology, we achieve the specified requirements. The mechanical structure boasts a new design, with components primarily formed through stamping or bending, offering advantages such as excellent rigidity, light weight, and interchangeability. The transmission method ensures reliable operation and convenient maintenance, suitable for conveying bottles with diameters ranging from Ø40 to Ø110mm. The electric control system, utilizing PLC on the rinsing-filling-capping tri-block, governs the operation of the entire container conveying buffer system. It automatically handles functions such as running speed acceleration, deceleration, and automatic buffering.

Features:

• The bottle belt is synchronously tracked with the host or upstream and downstream equipment, all controlled by the system.
• Ensures a smooth conveying process with no bottle falling, jamming, or blocking.
• Optionally, a buffer platform can be set in front of the labeling machine, typically with a buffering time of 1-2 minutes as needed.
• During PE label replenishment, the filling process continues, storing filled bottles on the buffer platform. Once replenishment is complete, the labeler initiates labeling, resuming synchronous production.
• After replenishing, the labeling machine accelerates to fill the platform with labeled bottles and then resumes synchronous production speed.
• The conveyor belt structure features modular design with interchangeable parts, offering compactness, low noise, ease of installation and maintenance, and adaptability for various capacities and bottle types.
• The electric control design is advanced and flexible, allowing customization based on customer requirements to enhance transportation smoothness.
• Control switch positions are thoughtfully arranged according to the conveying system layout or customer preferences, ensuring user convenience during operation.

Technical parameters: