A complete beverage machinery line is generally divided into four core modules according to the production process: pre-treatment, filling and capping, post-treatment, and auxiliary supporting systems.
I. Pre-Treatment Module
1. Raw Material Pre-Processing Unit
For solid raw materials such as fruits, vegetables, and grains, the line is equipped with cleaning and peeling machines, crushing and juice extraction equipment, coarse filtration and residue removal devices, and homogenizing and emulsifying machines. For liquid raw materials such as syrup and flavoring agents, precision metering, mixing and dissolving, and filtration equipment are configured.
2. Water Treatment Unit
Pre-treatment equipment includes sand filters, activated carbon filters, and precision filters. Deep purification equipment such as reverse osmosis (RO) and electrodeionization (EDI) is combined with ultraviolet or ozone sterilization devices to meet the hygiene standards for beverage production water.
3. Blending and Mixing Unit
This unit includes blending tanks, holding tanks, and inline emulsifiers to complete the precise proportioning and mixing of sugar solution, fruit juice, additives, and other components.
II. Filling and Capping Module
1. Integrated Washing-Filling-Capping Monobloc
The mainstream configuration is a 3-in-1 or 4-in-1 monobloc unit that integrates bottle washing, cap washing, filling, and capping. Depending on the product type, filling machines are classified into atmospheric pressure fillers for mineral water and pure juice, negative pressure fillers for carbonated beverages, and hot fillers for tea drinks and functional beverages. Standalone machines can also be flexibly combined according to production line requirements.
2. Supporting Capping Equipment
This includes screw capping machines, crown cap sealing machines, and tamper-evident cap sealing equipment to meet the capping requirements of different packaging containers.
In these filling and capping units, components such as filling valves, bottle grippers, capping heads, and star wheels must maintain high dimensional accuracy and wear resistance under continuous operation. Hansheng Automation provides custom machining of these parts based on customer drawings or samples.
III. Post-Treatment Module
1. Sterilization and Cooling Unit
Hot-filled products require spray cooling tunnels to reduce bottle temperature and consolidate sterilization. Aseptic cold-filled products do not require additional thermal sterilization, but they need an aseptic air system to maintain a clean packaging environment.
2. Packaging, Coding, and Inspection Unit
This includes inkjet printers for production dates and batch codes, labeling machines, sleeve labeling machines, and laser coding equipment. It is also equipped with quality inspection devices such as liquid level detectors, cap sealing integrity testers, and metal foreign object detectors.
3. Cartoning and Palletizing Unit
This unit includes semi-automatic or fully automatic cartoning machines, case sealers, palletizers, and shrink film packaging machines to complete the collective packaging and stacking of finished products.
IV. Auxiliary Supporting Module
1. Hygiene Assurance Unit
A CIP online cleaning system is configured for automatic cleaning and disinfection of production line piping and equipment. Air showers, pass boxes, and purification air conditioning systems are also installed to maintain the required cleanroom level in the production area.
2. Power and Control System
This includes variable frequency drive motors, air compressors, and PLC master control systems to achieve automated line operation and parameter regulation. Sensors, flow meters, and other detection components are also equipped to ensure precise and controllable production parameters.
3. Waste Treatment Unit
This includes residue conveyors and small-scale wastewater pre-treatment equipment to handle solid waste and production wastewater generated during the process.
