What key equipment does a fully automatic beverage bottle packaging line usua...
The core equipment of a fully automatic beverage bottle packaging line forms a complete closed loop "from empty bottles to finished boxes." Each device is connected by conveyor belts and works in coordination with sensors and control systems to achieve continuous operation.
Bottle Unscrambler
As the "front entrance" of the packaging line, the bottle unscrambler sorts disordered empty bottles (PET, glass, etc.) into a uniform orientation (bottle mouth upward, consistent direction) and conveys them to the next stage. Common types include the turntable type (for small to medium bottles) and the chain plate type (for large-capacity or irregularly shaped bottles). The core technology involves returning bottles to the correct position using levers, guide plates, or centrifugal force. It must adapt to different bottle diameters (typically adjustable from 50–100 mm) to prevent jams or inversions. The unscrambling speed must match the downstream filling machine's capacity (generally 50–600 bottles/minute).
Filling Machine
Filling machines are categorized based on beverage characteristics: normal pressure fillers (for mineral water), negative pressure fillers (for juice, to reduce oxidation), and isobaric fillers (for carbonated beverages, to prevent bubble overflow). The core component is the filling valve assembly, which achieves precise volume control (error ≤ ±1%) and is equipped with anti-drip devices (e.g., silicone seals). For hot-filled beverages (e.g., tea, 85–95°C), the machine uses high-temperature-resistant materials (e.g., 304 stainless steel) and anti-scald designs. Beverages containing particles (e.g., fruit juice) require large-diameter filling channels to avoid clogs.
Capping/Sealing Machine
This equipment seals bottle mouths and is classified by cap type: capping machines (for plastic screw caps) and sealing machines (for metal caps, e.g., beer bottle crowns). Capping machines ensure consistent tightening torque (adjustable from 0.5–5 N·m)-too loose causes leaks, while too tight may deform the bottle or crack the cap. Sealing machines use dies to crimp metal caps onto bottle mouths, ensuring a secure seal without damaging the bottle. Some machines feature automatic cap sorting via vibration plates and cap-missing detection sensors (which halt operation if caps are absent).
Labeling Machine
Labeling machines apply labels (self-adhesive, shrink film, sleeve labels, etc.) with precision. Common types include self-adhesive labelers (for flat or curved bottles, e.g., mineral water) and sleeve labelers (for neck or full-body labels, e.g., shrink-wrap labels). Key technologies include positioning accuracy (label offset ≤ ±1 mm) and smooth application (no bubbles or wrinkles). Self-adhesive labelers synchronize label and bottle movement using suction wheels and pressing rollers, while sleeve labelers rely on heat shrink furnaces to tighten labels, with strict control over sleeve positioning (especially bottle mouth-to-label distance).
Inkjet Printer/Coding Machine
These devices print production dates, batch numbers, and expiration dates on bottles or caps. Common types include laser coders (for PET bottles and metal caps, offering durable, consumable-free marking) and inkjet printers (for glass bottles, with lower costs). Print clarity (character height adjustable from 1–10 mm) and positional accuracy (e.g., bottle shoulder or base, deviation ≤ ±2 mm) must be ensured, along with online character verification (using visual sensors to detect missed or incorrect prints).
Light Inspection Machine/Visual Inspection System
As the quality "gatekeeper," optical inspection removes defective products. Light inspection machines use backlighting to detect foreign objects (e.g., glass fragments, hair) and abnormal liquid levels (too high/low). Visual systems employ high-definition cameras (2–5 megapixels) to identify label errors (skew, missing, or incorrect versions) and cap defects (broken or missing caps). Inspection speeds must sync with the production line (up to 600 bottles/minute), and automatic rejection devices (e.g., pneumatic push rods) must achieve ≥99.9% accuracy.
Cartoning Machine
Finished labeled bottles are packed into cartons or plastic crates in fixed quantities (e.g., 6 bottles/pack, 12 bottles/box). Types include grabbing-type (for lightweight bottles like bottled water) and pushing-type (for heavy bottles like glass). Grabbing-type machines use mechanical arms or suction cups (silicone or vacuum) to avoid bottle deformation, while pushing-type machines use baffles and guides to ensure orderly packing. High-end models automate carton forming (from cardboard to unpacking) and bottom sealing, reducing manual intervention.
Carton Sealer
Cartons are sealed using tape (efficient for standard cartons) or hot melt adhesive (better for heavy or cold-chain cartons). Key requirements include sealing accuracy (centered tape/glue line, deviation ≤ 5 mm) and flat folding at both ends to prevent transport damage. Machines must accommodate varying carton sizes (adjustable length: 200–600 mm) with quick changeovers (≤5 minutes).
Palletizer
Palletizers stack sealed cartons into stable loads (4–8 layers) for storage and transport. Common types include robotic arm palletizers (flexible, for multi-specification cartons) and coordinate palletizers (fast, for single specifications). Preset stacking patterns ensure stability (meeting anti-dumping standards), and automatic pallet feeders are included. Palletizing speeds range from 5–20 boxes/minute, compatible with standard pallets (1200 × 1000 mm).
Integrated Operation
These devices operate as a cohesive system-e.g., filling machine speed is synchronized with the bottle unscrambler and labeler via PLC control. If a fault occurs (e.g., bottle jams), upstream equipment slows or stops to prevent backups. To support small-batch, multi-variety production, equipment must offer quick changeovers (e.g., label reel swaps, one-click filling volume adjustments), with changeover time directly impacting production line flexibility.