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Juice Filling Machine

Juice filling machine is to fill fruit juice, tea In Bottles/Cans. It Is Usually Hot Filling Machine. Non-Carbonated Soft Drink such as juice, tea drink, ready-to-drink tea and coffee, functional drink (sport drink, nutritional drink, value-added or flavoured water), and non-alcoholic beer can be filled.

Principle of Juice Filling Machine

The filling principle of the juice filling machine is negative pressure/vacuum filling. Vacuum filling: when the filling tank is under normal pressure, use the vacuum reflux system to pump air from the bottle to form a vacuum. When the vacuum reaches a certain degree, the liquid flows into the bottle to start the filling.

Structure of Bottle Filling Machine

A juice-filling machine consists of a machine frame, a rinsing mechanism, a filling mechanism, a capping mechanism, a filling machine controller, a bottle conveyor system, and a piping system.

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 Juice 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.

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. And then filling valve contacts the bottle mouth.  Suction pipe in the filling valve sucks air from the bottle to form a vacuum in bottle. When the vacuum reaches a certain degree, the liquid flows into the bottle from the filling tank to start the filling. When the liquid filling level reaches the height of the suction pipe, the filling stops. And under the action of the cam, the bottle will lower and leave the 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 Bottled Juice Production Line

Q1: Can The Juice Filling Machine Fill Carbonated Juice Also?

No.

A carbonated drink-filling machine is a counter pressure filling machine, while a juice-filling machine is a negative/vacuum filling machine.

A counter-pressure filling machine can fill juice, but a negative/vacuum filling machine cannot fill carbonated drinks.

Q2: Can Plastic Bottles, Glass Bottles, And Aluminum Bottles Be Filled On One Machine?

No. Because different bottle and cap materials require different filling and capping mechanisms.

For instance, we fill plastic bottles with a bottleneck clamping system and glass bottles with a bottle bottom supporting system.

To customize your machine, in addition to the bottle material and size, you also need to tell us the cap material, such as plastic cap, crown cap, aluminum cap (short aluminum cap or high aluminum cap), twist-off caps, etc.

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: My Juice Has Fruit Granules, Can This Juice-Filling Machine Fill It Also? How About The Jam?

Yes, but there are conditions.
If the size of fruit granules is less than 3 mm, we can use the standard 3-in-1 unit juice filling machines (filling the fruit granules and juice together). If the size of fruit granules is more than 3 mm, we need to adopt the 4-in-1 unit juice-filling machines (filling the fruit granules and juice separately).

In contrast to juice-filling machines, jam-filling machines typically use position-type filling because jam has a high viscosity.

Q5: What Is The Filling Temperature Of The Juice Filling Machine?

According to the filling temperature, the juice filling machine has the hot filling and the aseptic cold filling.

Description Advantages Disadvantage
Hot Filling Machine Hot filling refers to sterilizing the juice by ultra-high temperature instant sterilization first, then filling it into the pre-sterilized clean bottle while hot and sealing it while hot. Hot filling is commonly suitable for high-acid juice and tea drinks. the machine is easy to operate, the juice taste is stable and easy to control, the juice shelf life can keep long. the long heating time makes the juice lose a lot of heat-sensitive ingredients and has a bland taste. The filling container should be hot-resistant, which increases the container material cost.
Aseptic Cold Filling Machine The aseptic cold filling refers to rapidly cooling the sterilized product and filling them. The aseptic cold filling is a unique form of cold filling, fill the product into the pre-sterilized container under an aseptic state. After sealing, there is no need for sterilization and cooling, and they can reach a long shelf life without preservatives and refrigeration. because the product is heated instantaneously, the product has a fresh taste and good flavor, low container material cost, less loss of heat-sensitive ingredients, does not produce a heating odor. It is widely applicable to different juice products. equipment operation is complex, equipment cost is high stringent requirements for the filling environment's cleanliness.

Q6: What Pre-Treatment Equipment Is Available Before Filling?

Based on the different raw materials, we can divide the preliminary treatment equipment into the fresh juice preliminary treatment and the concentrated juice preliminary treatment.

The working process of the fresh juice preliminary treatment: washing machine- crusher- juicer-filter-homogenizer- degasser-concentration-sterilization.

Different fruits have slightly different pre-treatment equipment.

The working process of the concentrated juice preliminary treatment: sugar melting-syrup filter-mixing tank- double filtration-homogenizer-degasser-sterilization equipment.
The pre-treatment equipment is slightly different for different juice formulations.

Q7: Do I Need To Purchase Sterilization Equipment After Filling?

After filling, hot filling juice needs the bottle inverse sterilizer and the spray sterilization cooling tunnel.
After filling, the aseptic cold filling juice does not require sterilization and cooling.
The bottle inverse sterilizer is special supporting equipment developed according to the process characteristics of the high-temperature filling production line. After filling and capping, it tilts the products and uses the high temperature of the products to sterilize the bottle mouth and the inner wall of the bottle cap within a set amount of time to ensure product quality.
The product in the conveying process can implement automatic bottle inverse, delayed sterilization, and automatic standing. The process is stable and reliable, and the sterilization time is also adjustable according to needs. In the sterilization process, only the high temperature of the beverage in the bottle sterilize the bottle mouth and the inner wall of the bottle cap, without increasing any heat source to achieve the purpose of energy-saving.

After the bottle inverse sterilizer, we need the spray sterilization cooling tunnel to cool the hot filling juice to room temperature. Spray sterilization cooling tunnel, also known as pasteurization tunnel. The tunnel consists of preheating areas, sterilization areas, and cooling areas. We can make different process design according to the requirements of products. Spray sterilization has the advantages of automatic program control, convenient operation, stable and reliable operation, beautiful appearance, and so on. It is ideal sterilization equipment for a modern beverage factory.

Q8: 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.

Non-Carbonated Beverage Market

The global non-carbonated soft drinks market is equal to 242 billion USD in 2021. Until 2024, the drinks market in the world is expected to reach 413 billion USD.
The global bottled water market is growing at a CAGR of 4.7% during the forecast period 2019 – 2024.

Trend Of Non Carbonated Soft Drink

Owing to the rising health consciousness, consumers are increasingly embracing non carbonated drink such as fruit and vegetable juice, low sugar drink, or other fortified drink with health benefit. Fruit and vegetable juice have became one of the fastest-growing segment in the beverage industry.
The increasing number of professional bodybuilders, athletes, and fitness or sport enthusiasts driving the functional drink market forward.

Experts estimate that there is about 68% of the world’s population has lactose malabsorption. Total number of vegans, vegetarians, and other related categories is close to 14% of the world’s population. Thus the Plant-based and Lactose-Free Drinks have been increasingly becoming popular.

Impact of Covid-19

People pay more attention to their immunity and health. Consumers believe that functional and nutritional products might benefit the body’s defenses and immunity, thereby contributing positively to the health drink market growth.

Make Non-carbonated Drink

In beverage industry, there are some ways to make the drink.

Fresh Fruit & Vegetables

concentrate

herbal, cocoa bean...

Powder

What Material Are Needed For The Juice 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 juice 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 Non Carbonated Soft Drink business no matter in machines, raw material, or the factory design.

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