1200BPH (5L) Automatic Bottled Water Filling Machine - Turnkey Production Line for Mineral & Pure Water

1 Summarize: BY12-12-5E PET bottled water 3 in 1 filling machine and capping system into a whole machine. It is PET 5L bottled water filling machine developed and designed with the leading domestic level, which is on the base of foreign advanced technology, according to the requirements of the filling process of the domestic pure water, mineral water and other drinks.

1.1 Linear Washer Model: LW-4

• Washing Heads:4pcs
• Washing Capacity: 400BPH
• Under PLC control, full-automatic working
• Sensor control, no bottle no washing
• SUS304 contact parts
• 304 Stainless steel construction
• Dimension: 1400*1300*1850mm
• Weight: 180kgs
• Power: 0.37Kw

1.2 Linear Filler Model: LF-4

• Filling Heads: 4pcs
• Filling Capacity: 400BPH ; 5L bottle
• PLC control, full-automatic working, filling volume adjustable
• Touch Screen control panel, easy operate
• Sensor control, no bottle no filling
• SUS304 contact parts & liquid tank, stainless steel filling pump
• 304 Stainless steel construction & frame
• Dimension: 1400*1300*1850mm
• Weight: 250kgs
• Power: 0.37Kw

1.3 Screw Caps Capper Model: CP-1E

• Capping heads: 1pcs
• Capping Capacity: Max.500 bottle per hour
• Suitable to PET screwed Capping
• System under PLC control, full-automatic working
• No bottle no capping
• All 304stainless steel construction
• Machine Dimension: 1000×1300×1850mm
• Weight: 150kg
• Power:0.5kw

2. Structure characteristics

2.1 Frame and working table: Machine body is welded by steel structure, 304 stainless steel surface coating, 304 stainless steel frame, and stainless steel adjustable feet

2.2 Bottle conveying system:The bottle conveying system adopts bottleneck locking feeding control with 304 stainless steel star wheels, except the bottle output star wheel. The air conveying system will deliver the empty bottle into the bottle feeding star wheel.Bottle output adopts non-locking structure, which can avoid adjusting the height of conveyor chain because of the different height of different bottle design.When need to replace the bottle of different diameter or height, users can only replace the poked-wheel.Through the air conveying, the bottle enter the bottle star wheel, thereby to ensure the reliability of operation of the bottle.

2.3 Rotary rinser:There are 12 bottle rinsing heads. The bottle rinsing cramps are of stainless steel clipping structure, which is out of touch of the screw thread of bottle mouth, with stable bottle clipping and high-efficient bottle rinsing.

2.4 Filling part:There are 12 filling valves in the filling machine, and the beverage contact parts are made of 304stainless steel. The outer and inner surfaces of filling cylinder have been treated by mirror finish, with high speed and large flow, high precision filling and filling speed and accurate level.

2.5 Capping part:There are 5 capping head in the capping part. The cap screwing part applies Germany technology with magnetic capping. It can protect the system from overloading, with stable & reliable capping torque. There are no problem of cap biting, higher cap, crooked cap and curling cap.The capping slide is of 304ss structure with photoelectric switch, which can automatically control the start-up or shutdown of the unscrambler. If there’s no bottle, bottle feeding will stop; if no cap for capping, the machine will stop automatically. Cap testing device is installed in the unscrambler. It can automatically feed the caps combined with the cap feeder. 

2.6 Driving system:The main driver uses the motor to drive to the speed reducer, and then drive the whole machine to run. Variable frequency speed control and each moving components drives with super strong pressed oil nylon gear.

2.7 Electric control system: Sealed independent electric control box with stainless steel material, imported PLC, frequency converter, relay, photoelectric switch, inductive switch relay element, touch screen operation panel, imported pneumatic components

2.8 The whole machine adopts centralized dry oil lubrication system, which makes the equipment maintenance and the maintenance more convenient.

3. Structure:The whole transmission of the BY12-12-5E adopts bottle neck hang-up design with screw from bottle feeding to bottle capping. The whole machine is composed of the following parts:

1. Frame and sealing window   2. Transmission and lubrication

3. Filling components          4. Bottle feeding system

5. Gas path system            6. Electric control system

7. Rotary capping system        8. Bottle washing components

3.1 Operating process: The bottles will be transmitted by the conveying chain and divided into suitable spacing after sorting by the bottle feeding screw and star wheel; the bottle washing clamp on the washing rotary tray will clamp the bottle neck to overturn 180°along the guide rail to make the bottle mouth down. In a specific region of the bottle washing part, sterile water will be sprayed from a special nozzle to clean the inner wall of the bottle; the bottle will be drain and then will be turn over 180°by the clamp. The cleaned bottle will be transmitted to the filling part through the bottle star wheel. In the filling part, the bottle neck will be locked by the bottle hanging plate; the bottle will be lifted by the lifting component to overcome the role of filling valve spring and the machine start filling; after finishing filling, the bottle will be lowered and the fill valves leave the bottle. The filled bottles will be transferred into the rotary capper by a neck handling star wheel. Anti-rotation bladeson capping machine will seize the neck of bottle to prevent it from rotation and hold it in an upright position. Thetwiston capping head will make revolving and rotating movement along with the machine to finish the complete capping process of cap picking, placing, twisting and disengaging under the control of a cam. A discharge star wheel discharges finished bottles onto discharge conveyor belt to be conveyed out of the 3 in 1 filling machine. The whole transmission adopts bottle neck hang-up design.

3.2 Running process: PET bottle will be (1) sent into the main machine by screw (2) and divided into suitable spacing and transmitted to the washing machine (3) after washing (4) bottles will be sent to (5) the filling machine by the filling star wheel (6) the bottle clamp of the filling machine will lock the bottle and lift the bottle to be sealed and the filling valves is on and start filling. After finishing filling, the bottle is lowered and (6) transmitted to the rotary capper by the filling and sealing star wheel (7) after finishing capping, the bottle will be discharged by the bottle feeding star wheel (8) and sent to the discharging belt (9) finally enter the next working procedure(or machine).

4. Equipment structure and function

4.1 Washing machine

4.1.1 Structure:The washing machine is mainly composed of spindle, water ring, water tank and bottle clamp.

4.2 Washing technique:Washing schedule (12heads) Production capacity: 1500BPH (5000ml/bottle)

4.3 Washing schedule

4.4 Washing material:Sterilized water or disinfected water (according to the product process requirements)

5 Main structure

5.1 Bearing component: The component is an important part of the machine, which supports the weight of the main body ofthe machine.The transmission gear (1) provides power; and the power goes through the shaft(3) and is transmitted to the bottle clamping. The shaft seat (2) is fixed and the weight of the whole machine is supported by the shaft seat.

5.2 Water ring: Bottle washing medium enter by part 4 and part 5 plays a watershed function; the washing angle is defined by part 5’s structure and the bottle washing medium is divided into multiple ways by part 5 to achieve bottle washing. Part 2 is used to ensure that the washing angle is unchanged in the whole machine, and part 5 is used to tighten the angle. Part 3 is fixed by the anti rotation component.

5.3 Sink component: The sink component is used to collect the washing medium, in order to avoid the waste of washing medium and achieve concentrative discharging and recovery; washing medium flows back in part 2 through part 1. Part 5 is used to connect the upper and bottom of the sink; part 4 is bottle clamp turnover guide rail, which is supported by part 4; part 6 is the upper cover, which is conducive to the recovery of the washing medium.

5.4 Bottle clamp: The bottle is run by the clamp along with the turning guide rail. Part 5 is the clamp, which is different according to different bottle neck; part 4 is a spring to ensure the clamp to lock the bottle; part 2 is the clamping rail column, which will run along with the turning guide rail. The whole bottle clamp is installed on the part 1 supporting tray by part 3.

6. Filling machine

6.1 Equipment composition :The Filling machine is mainly composed of by bearing component, liquid cylinder, hydraulic cylinder lifting device, bottle lifting device and filling valves etc; in the device plays the role of filling material in the bottle; the filling machine is used to fill the material into the bottle; all the components contact to the material are made of stainless steel and special materials production, which is in line with the food sanitary requirements.

6.2 Filling technique: Washing schedule (12heads) Production capacity 1500BPH (5000ml/bottle)

6.3 Filling schedule

6.4 Main structure

6.4.1 Bearing components: This component is one of the important components of the filling machine, which is used to transmit the power and support the weight of the whole machine.The gear (1) transmits the power to the hydraulic cylinder lifting device through the hollow shaft (2). The bearing seat (3) can support the whole weight of the filling machine.

6.4.2 Liquid cylinder component: The liquid cylinder is an important part of the filling component, which is used for temporary storage of liquid material, and to make a certain pressure difference in the filling valve. Hydraulic cylinder component is composed of the liquid inlet pipe (1), the liquid cylinder head (2), the liquid level floating ball (3), the mirror (4), and the liquid cylinder (5). Hydraulic cylinder is used for liquid storing; the liquid level floating ball controls the liquid level in an appropriate range and can manually observe the liquid level through the mirror; liquid inlet pipe is connected with the gas valve. When the liquid level in the cylinder is in a low level, the gas valve will open and let the liquid get into the cylinder; when the liquid level in the cylinder is in a high level, the valve closes. The filling valve, the bottle lifting device and the liquid cylinder lifting device are installed at the bottom of the liquid cylinder.

6.4.3 Liquid cylinder lifting device: The lifting device is another important component of the filling machine, which is used to support the cylinder and adjust the height of the cylinder. Rotate the regulating chain to adjust the lifting device.

6.4.4 Bottle lifting device: The device is a mechanical device. When is in normal production, the roller (2) is fixed on the guide block (5) of the lifting device, under the pressure of the the lifting cam (7) and the lower pressure cam (6), drivesthe hanging bottle plate (4) to lift or drop. A sliding bearing is equipped in the guide block, which can slide up and down on the guide rod (3); the cam support (8) plays the role of supporting the cam and the weight of the lifting device. Loosen the lock nut (1) to adjust the height of the cam and the board.

6.4.5 Filling valve: This component is designed for atmospheric pressure reflux filling. All the valves of the machine are installed in the hydraulic cylinder. When the filling valve does not move, bottles will move in line or up and down; filling material flow into the filling valve through the luquid inlet and the spring is open by the bottle in the mouth pad, and finly the material enter the bottle. The filling valve is sealed by the spring when it is under the condition of non filling. All possible connection with outside is sealed with seal ring.

7. Rotary capper

7.1 Constructure：The rotary capper is composed of rotary capping device, rotary capping assembly, rotary capping head and rotary capping principal axis.The reducer drives the rotary capper to the gear, and transmits the power to rotary capping head through the rotary center column, and drives the cutting wheel to rotate so as to drive the rotation of the cap pulling plate.The caps are sorted by the unscrambler and transmitted to the cap pulling plate through the cap discharging guide rail; the rotary capping head moves up and down by the rotary capping cam and rotates to the tangent position of the cap pulling star wheel, and then pick up the caps; when the rotary capping head lifts again, and rotates to the capping machine with the bottles, the bottle rotates together and finished capping.

7.2 Rotary capping machine main structure

7.2.1 Rotary capping assembly：The rotary capping cam (2)is installed and fixed on the roof and the rotary capping assembly is installed on the supporting ring(6), which rotates along with the supporting ring; meanwhile the roller( 3)scrolls along the cam curve and drive the winding gear(4) move up and down.

7.2.2 Rotary capping head：The shell of the rotary capping head is screwed at the lower end of the lifting shaft by thread; when lifting axis revolves, rotates and moves up and down, the rotary capping head will move synchronously the same. There are two units of adjacent magnetic column (1) with opposite magnetism installed in the rotary head; under the effect of the magnetic suction force, the corresponding rotary capping torque is assured; the magnitude of the torque is guaranteed by adjusting the distance between the two groups of magnetic bodies. When the rotary capping torque exceeds the fixed value, the relative sliding between the two groups of magnets will stop the rotation of the rotary capping gear ring. The spring in the rotary head is to set to force dowanward to the rotary capping. The rotary capping mould(2) is allowed to compress 2 ~ 6mm along the axial; the lid spring(3) is to prevent the bottle and remove the rotary capping mould, so as to ensure the normal operation of the machine.

Notes: the Magnet adjusting ring (4) and the cap rod (5) has been adjusted before they leave the factory, please do not adjust.

7.2.3 Rotary capping principal axis：The bearing bracket (3) is mainly to support the rotary capping machine; the power transmitted by the gear (4) to the rotating central column (1), thereby to drive the rotation of the capping machine. The power of the cap pulling assembly is also derived from this. Part 2 and part 5 support the whole weight of the capping machine. The height of the capping machine can be adjusted by loosening the round nut and rotating the handle.

7.2.4 Cap pulling assembly：The cap pulling assembly is to divide the caps to the rotary capping head after sorted by the cap sorting device. The transmission power is provided by the pin tooth between the rotary capping machine and the cap pulling assembly.

7.2.5 Cap discharging guide rail：When the caps enter the guide rail, it means that they are in the cap pulling plate. To avoid any problem, an anti - back cap wheel is arranged on the guide rail to ensure that the caps are right. A pair of photoelectric switches is arranged on the guide rail, and when no caps are detected, the main machine must stop.

7.2.6 Back cap detecting device：Back cap detection should ensure that the star wheel and the back cap device contact 3 ~ 5mm, in order to ensure the rapid capping.

7.2.7 Cap sorting device：The cap sorting device is to put messy bottle cap into the hopper (2) with special cap sorting plate 3, under the rotation of a motor (5), to make the caps discharged in accordance with the correct orientation arrangement to export and then sent to the cap dropping guide rail; the turnover caps will fall back into the cap tube (1) with an air blowing nozzle, which can blow the caps into the cap sorting device and to be re-sorted. Part 4 is used for cap stirring. Detection device (6) is equipped on the signal support plate, which will automatically alarm when there is no cap in the cap sorting device.

Note: according to the configuration of users (with cap sterilizer), a cap sorting device may not be equipped.

8. Bottle conveying system: The bottle conveying system consists of a set of bottle feeding screw component (1), a feeding star wheel (2) and two transitioning star wheel( 5), a guide plate assembly (4) and bottle output star wheel (6), and a conveying chain frame (7).The bottle feeding screw is to divide the input bottle delivered by the conveying chain into a certain space.The bottle feeding star wheel is to convey the bottle from the deeing screw into the bottle washing machine.The transitioning push wheel is to make transition from bottle washing to bottle filling and to bottle capping. The structure of the two push wheel is the same.The guide plate assembly is to protect the bottle with the push wheel. The push wheel and the plate should keep smooth in transmission without big shake, which will make the bottle material overflow. In the production process, if bottle material overflow is serious, users should immediately check and adjust the relevant parts. If users want to replace the bottle with different diameter of the bottle mouth, the relevant push wheel and guide plate should be replaced too.The bottle output push wheel is to transmit the bottle after finish capping to the conveying chain.The conveying chain frame is to keep providing the main machine with bottles and convey the bottle after filled and capped into the 3 in 1 machine.

8.1 Bottle feeding screw: This component is to divide the bottle from the conveying chain into fixed space. If users want to change the bottle type, component (1) should be replaced and adjusted to appropriate place and locked. The coupling (2) is to ensures the power of the gearbox (3) can still be obtained when part 1 is adjusting. The transition gear (4) is to deliver the power from main engine to the gearbox (3), and change the vertical rotation of the transition gear assembly (4) into horizontal rotation along the screw. When the height of the bottle body is adjusted, the height of the screw can be adjusted by the waist hole of the screw support frame; loosen the nut (5) and the height of the gearbox (3) can be adjusted.

8.2 Star wheel assembly: The star wheel assembly plays an important part in the conveying process. There are one bottle feeding star wheel, two transitions star wheel and one bottle output star wheel assembly in the whole bottle conveying system. The structure of all the star wheel is approximately the same; the bottle output star wheel is to support and protect the transmission of the bottle, the other star wheels are for transmission of bottleneck hanging. Part 3 is the star wheel. When the bottle mouth changes, it (3) needs to replace by loosening the screw; when the star wheel is misplaced and needs to adjust, release the handle (1), keep the plate (2) loose; for that there is no waist holes in the bearer, adjust the star wheel (3) to the appropriate location, re-lock the handle (1. 5) to make the shaft seat fixed and transmit power with the gear (6).

8.3 Conveyor chain frame:Conveyor chain frame is to transmit the bottle after washing, filling and capping to the follow-up packaging link. Conveyor chain frame is arranged in 3 in 1 machine working table; when the bottle type changes, the height of the bottle also changes and the height of the chain frame needs to be adjusted; if bottle diameter changes, adjust space of two sides of the guide.

9. Hermetic window : The hermetic window is to prevent personnel in the operation process encountered the rotating part of the machine, and also can prevent the bottle washing medium which may has stimulating effects of the liquid viscosity to the skin from unnecessary damage; a observation window is provided on the hermetic window, users can observe the operation of the whole machine from the window;when the machine needs to be repaired and maintained, users can open the hermetic window and get into the machine.

10. Centralized lubricating system: This machine is equipped with a manual lubricating system. The lubrication point is shown below.

11. Gas path: Provide gas source for different parts.

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