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Carbonated Beverage
Filling Machine

Carbonated beverage filling machine is to fill carbonated beverage in bottles/cans. Carbonated beverage is a category of non alcoholic drink consists of cola beverage, fruit-based flavor drink, energy and sports drinks, and tonic water. Consumers like its acidic bite, pleasant tingling and cooling sensation with every sip. These fizzy drinks are also one of the best companions of certain foods.

Principle of Carbonated Beverage Filling Machine

Filling machine tank pressure is higher than atmospheric pressure. Fill CO2 into the bottles to make the bottle pressure equal to filling machine tank. Then fill drink into the bottle by its gravity.

Structure of Bottle Filling Machine

Carbonated Beverage Filling Machine consists of a bottle washing machine, a filling machine, a capping machine, a worktable, an inlet and outlet bottle arc plate, star wheels, motor drivers, a frame and control system. Bottle holder holds the bottle neck or bottom, then send it under the action of star wheel between bottle washing, filling and capping machines.

Bottle Washing Machine

Bottle washing machine consists of bottle washing clamp, upper turntable, guide rail, water distributer, protective cover, water spray device, water collecting tray. All parts in contact with the liquid is SS304 or SS316. The bottle wash clamp is integrally molded, and lubricating parts of the active part is from Igus. It is more durable than ordinary bottle washing clamp for 5 years.

Filling Machine

Filling machine consists of filling tank, filling valve, control ring, lifting device, etc. The liquid contact part is SS304 or SS316, and the thickness of the filling tank’s bottom plate is up to 30mm. The filling valve is Germany style and was manufactured by China’s top filling valve company.

Capping Machine

Capping machine consists of bearings, lifting worm gear components, transmission gears, capping heads, cams, machine reducers, etc. It is magnets torque, and the torque is adjustable. This capping machine is stable, and it has low cap scrap rate. When the cap type changes, only need to change capping head and seat. It is easy to adjust machine when change cap type.

Filling Process of Carbonated Drink Filling Machine

Air conveyor/conveyor sends bottles to star wheel. Star wheel sends bottles to bottle washing machine. There are bottle clamps on washing machine. Bottle clamps clamp the bottle neck and flips 180° along the guide rail to let the bottle mouth down. In the specific area of the bottle washing machine, washing nozzle sprays water into bottles to rinse the inner wall of bottles.  Star wheel sends bottles to capping machine. The stop knife on the capping machine locks the bottle neck, keeping the bottle upright and preventing rotation. The capping head keeps the revolution and rotation on the capping machine, and realizes the action of cap grabbing, cap covering, cap screwing and cap releasing under the action of the cam. Star wheel sends bottles from the capping machine to the bottle conveyor. Bottle conveyor sends bottles to next machine.

soda filling machine principle

After washing and draining, bottles flip 180° along the guide rail to let bottle mouth up. Star wheel sends washed bottles from washing machine to filling machine. The lifting device raises bottles under the action of the lifting cam. Bottles contact and press the filling valve, and then the valve opening device opens the filling valve. After CO2 filling, it forms counter pressure between filling tank and bottle, then carbonated beverage filling starts. Filling stops automatically when the liquid level reaches the vent. When the filling is done, the valve closing mechanism close the filling valve, and then vent cam prop up vent rod to release CO2 to finish the entire filling process. The lifting device lowers to let bottle leave filling valve.

Star wheel sends bottles to capping machine. The stop knife on the capping machine locks the bottle neck, keeping the bottle upright and preventing rotation. The capping head keeps the revolution and rotation on the capping machine, and realizes the action of cap grabbing, cap covering, cap screwing and cap releasing under the action of the cam. Star wheel sends bottles from the capping machine to the bottle conveyor. Bottle conveyor sends bottles to next machine.

Know More About The Soda Drink Production Line

Q1: What Container Can This Carbonated Beverage Filling Machine Fill?

PET bottles, Glass bottles, PET Cans, and Aluminum Cans.

Q2: How Does Carbonated Beverage Filling Machine Keep Constant Liquid Level in The Bottle?

The length of the vent decides the height of the liquid level. Keep the same vent length, bottle shape and size, the liquid level is always at the same height.

The liquid flows into the bottle along the bottle wall through the diverter umbrella, and the CO2 in the bottle returns to the filling tank through the inner hole of the vent. When the liquid level in the bottle reaches the height of the vent, the CO2 circuit is cut off and the liquid filling stops. By changing the length of the vent, we can adjust the level.

Q3: How to Fill Multiple Bottles at Once?

Bottles with the same neck size, and the bottle diameter difference isn’t more than 5mm, one set of filling machine can fill them all.

If the bottle has the same neck size, but the bottle diameter difference is more than 5mm, we will need the bottle change parts. Each set of bottle change parts is customized according to the bottle size. The bottle change parts include the bottle star wheel and bottle fixing parts.

If the bottle neck size is different, we will need the change parts mentioned earlier. Moreover, all parts in contact with the bottleneck. For example, the bottle neck holder, clamp, the capping head, and the seat.

Q4: How to Avoid Foaming When Fill Carbonated Beverage?

The filling valve quality, high syrup ratio of the beverage, and hot temperature are the main reason of the foaming problem.

When filling, the liquid is evenly filled into the bottle along the bottle wall through the diverter umbrella. At the end of filling, the vent cam props up the vent rod, and release the CO2 in the bottleneck slowly. So that release the pressure in the bottle to prevent foaming.

The ratio of water to syrup is 1:4 or 1:5.

The filling temperature of carbonated beverages is 3~5°C.

Q5: How To Make The Carbonated Beverage Temperature Be 3~5 Celsius for Filling?

The filling temperature of carbonated beverages must be 3~5 °C. Because low temperature enhances solubility of CO2.Before mixing with CO2, the mixture temperature of water and syrup is at 60 ° C.

We need to use a refrigeration unit to reduce the mixture temperature to less than 4 ° C. Usually we use plate type heat exchanger to achieve this. The entire cooling process is:

soft drink blending system

Q6: How To Mix Beverage with CO2?

Carbonator is to mix water, syrup and CO2 together. Water and syrup enter the carbonator machine from different pipelines and mix in the carbonation machine. After cooling by plate heat exchanger, mix with CO2. The workflow of the mixer is:

carbonator working process

Q7: What Is the Syrup Mixing Process?

There are two kinds of production processes for soda: one is to fill syrup into the bottle firstly, and then fill the carbonated water (water with carbon dioxide). This is double filling. The other is to mix the syrup and carbonated water quantitatively, and then fill the mixture into the bottle. This is one-time filling.

The double filling method is an older filling method. It is for the filling of pulp-containing soda. Because the pulp often jams the nozzle of the carbonator machine. It is not easy to clean pulp. Its disadvantage is that the syrup is usually inconsistent with the temperature of the carbonated water, and it is easy to stir up a lot of foam when fill carbonated water.

There are two types of one-time filling methods. The first is to add a particular amount of syrup and water to the beverage mixing tank and stir it evenly. After cooling, it is mix with CO2 in the carbonated mixer. This method needs the use of big beverage mixing tanks. To avoid the growth of bacteria, the mixed beverage must be chilled, carbonized, and filled promptly. The second is that the syrup and water flow continuously into the carbonator and mix well in proportion under the action of the proportional valve. Chiller cools the mixture to the standard temperature, and then the mixture mixes with CO2 to reach the specified CO2 volume before filling. The advantage of this method is that the ratio of syrup and water is stable, and the accuracy is high, and the product quality is consistent when the container capacity changes. In addition, because the mixing temperature of syrup and water is the same, the foaming is small, so only need to control the CO2 volume once.

The one-time filling method is now the mainstream filling method for carbonated beverages. If the carbonated beverage has granule ingredients such as pulp, the double filling method is better.

Q8: There Is a Warming Tunnel After Filling Machine, What Is This For?

The temperature of the filled beverage is around 5 ° C. The indoor temperature is around 25 ° C. The large temperature difference between the bottled beverage and the indoor temperature will cause the bottle body to condense water droplets, which will have an impact on later labeling, coding and packaging.

Warming tunnel uses the form of water spray at different temperatures to gradually warm the bottled beverage from 5 ° C to room temperature. After the bottled beverage coming out from warming tunnel, only need to dry bottles with a blow dryer, and then continue the later labeling, coding and packaging.

Q9: What Labeling Machine, Date Printer And Packing Machine Do You Need?

Plastic bottles usually use shrink labels and OPP labels.

Glass bottles are self-adhesive labels or bottle printed.

Plastic and glass bottles are available with ink printers and CO2 laser date printers.

Metal containers such as aluminum cans can use ink printers and fiber laser date printers.

If you are producing glass bottled beverages, a grab-type cartoning machine is a better choice. When the production line speed is low, manual packing is also an excellent choice with only one sealing machine. If the local carton packaging materials are more expensive, and there is not much restriction on plastic packaging materials, you can choose a shrink film packaging machine to save the cost of machines and packaging materials.

Market Of Carbonated Beverage

The global carbonated soft drinks market is equal to 440.56 billion USD in 2021. Until 2027, the drinks market in the world is expected to reach 607.25 billion USD . In 2019, carbonated drink got 50% beverage market share around the world.

The global carbonated soft drink market is growing at a CAGR of 5.1% during the forecast period 2020 – 2027.

Trend Of Carbonated Beverage

Definitely cola is the most popular beverage segment in the world. In 2019, it accounted for 55.8% share of the global revenue. Owing to the consumers rising health consciousness, zero or low calorie drink, low sugar drink, and natural ingredients added drink have been increasingly becoming in demand. Various notable companies launched small-size packaged drink. It is a new chance to win the market.

Product innovation is one of the most effective strategies for companies to enhance the revenue. Carbonated energy and sport drink, and fruit-based flavor drink are anticipated to have the fastest growth in the next 5 years. orange and lemon are the most preferred flavors.

Formula of Carbonated Beverage

According to different formulas and recipes, the carbonated beverage use clean water, flavor elements, sugar or other sweeteners, coloring agents, and preservatives.

Material For The Carbonated Beverage Filling Machine Line

Bottles

PET bottle preform. This is a compact form of a bottle. It can be made to bottle by the bottle blowing machine. It is easy to get the preforms from any country. The price is up to the preform weight, neck size, raw material price, and market.
Buying ready bottles from the bottle supplier is also common. In this case, there is no need to buy a bottle blowing machine.

Metal cans and glass bottles are used in high-class brand carbonated soft drink nowadays.

Caps

Plastic caps are usually for plastic bottles. The aluminum caps, crown caps, pull-ring caps are for glass bottles. Lids are for metal cans.

Plastic caps
aluminum caps
crown caps
pull-ring caps
lids

Labels

Shrinking labels(PVC&PET) are popular for middle-scale bottle filling production lines while the opp labels are good for big bottle filling lines. Because the price of opp labels is lower than shrinking labels, but the opp labeling machine is more expensive than labeling shrinking machine. Some brands use sticking labels. Self-adhesive labels and glue labels are usually for glass bottles and made from paper.

Packing Material

Shrinking film packing and carton packing are the main packing types.

Please contact us to share your idea.

We will help you to set up the Carbonated Soft Drink business no matter in machines , raw material or the factory design.

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