Hi, my name is John Lau but you can call me JL. I work as the Sales Director for iBottling.com.
Our company specializes in manufacturing machinery for bottling beverages - that's our logo, a bottle.
Let us bottle and sell your best-tasting creation to the world-wide market! For over 20 years we’ve been pioneering in the beverage industry as one of the leading providers of beverage machinery for food manufacturers around the globe. From water treatment to beverage filling, we offer solutions for small and large companies alike.
From South Africa to UK, Australia to Russia, and Argentina to Canada, Steplead has provided high speed 5 gallon machine solutions for many name brand companies with high-speed bottling systems 100 – 3,000 Bottles Per Hour output.
Steplead certified parts with additional warranty
Less maintenance
Less energy using lower engine speed and larger hydraulic pump.
Standard or customized washing configurations for Steplead fully automated washer system, available in static and inserting spray and flushing technique, innovative non-contact washing structure, proven high-quality mechanical structure, comprehensive washing, and sterilization system, with the longest time setting in industry, also accept tailored design requirement
Fully automated 5 gallon filler available for both linear and rotary structures, with heavy gauge stainless steel construction, equipped automatic cap hopper, sorter and feeding system. High accuracy filling levels with non-contact 2 stages fill system can be setup for any special voltage and frequency, while wide application range from 100 to 3,000 Bottles Per Hour.
Steplead B5G series offer wide application options and filling solutions with custom-build bottling plant that customer needs without custom costs.
Steplead B5G series provide full water bottling system design, not just production, but also installation, integration, and after services. With strong global support service for 5-gallon bottle filling machine, also spare parts, and field service options for water bottling plant, making our equipment an ideal fit for water bottling operations of all business sizes.
STEPLEAD will assign a dedicated project manager to give one-on-one assistance with all aspects of your anticipated equipment. Not only do we collect a lot of information regarding your packaging solution, but we also provide round-the-clock assistance to satisfy your needs and fulfill your deadlines, ensuring that the project runs successfully.
A project manager from STEPLEAD will provide the following services:
Create a project plan that includes all of the relevant information.
Follow up and evaluate project specifications on a regular basis to adjust the project schedule.
Provide practical assistance and support.
Prepare and arrange all of the project’s associated paperwork.
STEPLEAD offers a comprehensive packaging line turnkey service. As per the planned design arrangement, every equipment is smoothly and synchronously connected to the mechanical structure, electric wires, gas and liquid pipes. Our experienced experts will ensure that the performance, design, and engineering of all machinery is in perfect working order for the customer.
STEPLEAD manufactures and installs turnkey project solutions in the customer’s workshop, as well as providing training for all integrated turnkey solution packaging line equipment, including operation, maintenance, documentation, and other essential and necessary support.
Please contact us if you have any more questions about our turnkey solution packaging line equipment.
Email: [email protected] | Phone: (86) 8314-3479
A STEPLEAD professional with more than 20 years of expertise will guide you through the machine installation process step by step. Following the installation of your machines or line, the expert will remain in your factory to ensure that everything is running properly and to teach your staff. After our expert has left, STEPLEAD will give timely and courteous support to you 24 hours a day, seven days a week.
The following services are provided by STEPLEAD expert:
Installation of machinery and equipment, as well as a filling line, at the customer’s plant.
To proceed with switching and preventative maintenance operations, synchronize and coordinate the timetable with engineers.
To improve the performance and stability of the machines, make the required engineering modifications to the machines and filling line.
Troubleshooting for machine malfunctions.
All scheduled operations must be documented in accordance with the relevant documentation policy.
Provide an on-site training course for all processes that are required.
Installation and customization of all machines in your plant will be handled by a STEPLEAD specialist. All of these actions will have one goal: to optimize the equipment in order to increase production capacity. STEPLEAD additionally guarantees that the expert will carry out regular operations for the whole production line and completely fulfill the customer’s production requirements.
Every customer will receive ongoing after-sales assistance from STEPLEAD. In addition, we offer a good guarantee on each equipment we sell, including workmanship, performance, and response time. STEPLEAD service departments keep hundreds of different components, ready for any urgent demand from customers, ensuring quick and efficient fulfillment of all parts orders, thereby minimizing downtime and productivity loss at the customer’s production.
To ensure a flawless installation, STEPLEAD service experts are all qualified with 15-20+ years of expertise. They also offer on-site training and assistance.
Following are the areas where specialist after-sales assistance will be provided:
Machines are installed at the customer’s factory.
Troubleshooting procedure
Troubleshoot electrical, mechanical, and software issues.
Maintain and restore a database of computerized machine history.
You might be interested in learning more about the STEPLEAD VIP Guarantee if one of your demands is to decrease downtime due to machine problems.
Food-grade SUS304, SUS316, POM, and silicone parts that fulfill sanitary requirements, as well as world-renowned electrical components, are the key materials utilized in our beverage equipment. We can also create any bespoke design for you based on your requirements.
STEPLEAD manufactures all of its equipment in its own facilities, which are LEED-certified and ISO and CE-certified. STEPLEAD is committed to environmental protection in all areas of operation by reducing waste in all manufacturing processes.
It takes only two hours to drive to the nearest major shipping ports, which offers the most cost-effective shipping rates and quick transit to nearly every country on the planet.
The following are the components of our facility:
Professionals and experts with extensive experience and expertise
Engineering assistance on-site
Material requirements are being planned (MRP)
Engineering of Production
Manufacturing and putting together
Testing of components and machineries
High-tech, high-precision machining centers
STEPLEAD offers OEM and ODM equipment and services that are custom-designed to meet your specific demands and objectives at the most reasonable costs. From single equipment to whole turnkey solutions, we have you covered. From concept to reality, you can count on high-quality machines and services to help you overcome your business’s limitations.
As a prominent packaging equipment producer in China. We attend a variety of training and events to keep up with the most sophisticated industry technologies and trends.
With the rise of the firm and the extension of the manufacturing line, the customer base develops. To optimize the customer’s advantage, STEPLEAD delivers an optimum solution with a customised design machinery project. Tailor-made service includes developing and adapting automated packaging systems, as well as our whole product line for diverse applications. Our experienced engineers will assess your goods, packaging requirements, and production demands, and then develop bespoke equipment to meet your specific requirements.
STEPLEAD is a modified version of STEPLEAD.
Equipment with a custom design
Procedures for manufacturing
Equipment modification and setup.
STEPLEAD guides customers of all sizes and stages reach their desired business.
We are committed to the success of our customers. Most of our clients come back for more equipment as their business develops and prospers. STEPLEAD machinery is made to order, whether it’s a filler, capper, water filter, blower, or labeler for your present line, a multi-station filling line, or a complete turnkey solution filling line.
Every customer can count on us to offer them with high-quality equipment and service. We also recognize that you could run across an issue and need help. A helpful and professional customer service representative will be on hand to provide a quick response. You can reach out to us at the following phone number and email address:
(+86-755) 83143479
[email protected] iBottling.com iBottling.com iBottling
The best way to experience our wide collection of production layouts for your project.
Here is a list of all the types of technical questions concerning 5 gallon bottle filling line that you can find.
5 gallon bucket sorting and capping operation guide
1. Basic requirements:
1.1 Employees should wear work clothes and caps neatly, wear employee ID cards correctly, and all operators should pass the physical examination.
1.2 The job site should be clean and hygienic, and empty drums and empty drum trucks should be neatly sorted and stacked.
1.3 Work tools and supplies should be stored in categories.
1.4 Trademarks, barrel stickers, labels, logos, and cleaning agents should be stored in categories and managed by special personnel, and the entry and exit should be registered.
1.5 The foreign barrels are picked out and stored separately.
2. Sorting and inspecting barrels
2.1 Goal: 100% pass rate for barrel loading
2.2 Visual inspection:
1) Check the barrel: The barrel should be free of pollution or damage. There shall be no scribbles or random additions of text or patterns, and no other labels and items shall be pasted. The outer wall of the barrel should be basically clean, and there should be no oil stains or other dirt that are difficult to clean, or irreversible discoloration, spots, etc. caused by corrosion and staining, and there should be no serious and obvious scratch marks on the barrel. The mouth of the barrel should be flat, free of nicks, thorns and depressions.
2) The inner wall of the barrel should be kept basically clean, and check whether there are foreign objects, different colors, moss, etc., and colored liquids in the barrel.
3) Smell the odor of the barrel body and the barrel, and there should be no odor or foreign matter. There must be no signs of impure water containing gasoline, diesel, vegetable oil, beverages, etc. If there are, they should be picked out and stored separately, and should not be mixed with other buckets.
4) The exterior is very dirty, and the moss in the barrel or the barrels with different colors and odors are picked out separately.
5) Drum label: complete without pollution and damage. The identification sticker is correct.
6) In case of a barrel that is controversial and difficult to judge on the spot, please ask the squad leader or quality control supervisor of the first district for instructions.
2.3 Handling of unqualified buckets
1) Broken barrels: After confirmation by the quality control department or warehouse management, they will be discarded and recorded.
2) Odour bucket: Clean it after picking it out, soak it in appropriate potion, soak it with activated carbon, hang a sign, confirm that it has no peculiar smell and pass the quality control inspection before use, otherwise it will be scrapped.
3) Scratch bucket: pick it out separately, restore it, and check for water leakage. It can be put into use if it does not leak and the appearance inspection is qualified, otherwise it will be scrapped.
4) If the appearance is seriously dirty, it should be stored separately, marked with a sign, and cleaned with alkaline water. To remove foreign objects and moss in the dirty bucket, it should be cleaned separately and used after passing the test.
Strictly distinguish between qualified and unqualified barrels, store them in categories and mark them.
3. Pull out the lid of the empty barrel
3.1 Workflow:
1) The cap pulling machine works normally, the chain runs smoothly, the cap pulling head and the barrel mouth are aligned correctly, and the cap pulling head must not damage the PC barrel.
2) Check whether the compressed air is normal.
3) After removing the lid, check whether the barrel mouth is flat, the barrel mouth must not be scratched, dented, there must be no residual sealing film, and the barrel wall must not be damaged.
3.2 Notes:
1) If the barrel is stuck, the cover cannot be pulled out, the alignment is not accurate, and the barrel is inverted, the power supply and gas source should be cut off and handled with care. Do not use sticks, sticks, knocking or prying to remove.
2) In the case of peculiar smell, serious pollution, damage, damage to the mouth of the barrel, or damage to the label, the barrels that do not meet the sorting standards should be removed.
3) Keep the production site hygienic.
4) After the shutdown, the equipment and production site should be cleaned. The production equipment on site should not be washed with water, and electrical safety should be paid attention to.
The first stage light inspection
1. Operational standards: Light inspectors must perform long-distance and near-distance vision tests, both of which should be 4.9 or above, and should be free of color blindness.
During operation, the inspection personnel should sit directly in front of the inspection table and look at the inspection table with both eyes.
1.1 Check the inside and outside of the barrel for contamination such as foreign objects, different colors, and odors.
1.2 Check whether the flatness of the barrel mouth is defective, the barrel body is required to be free of damage, no air bubbles and other quality abnormalities, and the unqualified barrels are picked out and rejected.
1.3 The labels on the barrels are complete, correct and not damaged. If the labels are defective, pick them out and label them again.
1.4 Smell the smell with the nose, there should be no peculiar smell.
2. Treatment of unqualified buckets
2.1 Strictly distinguish the qualified and unqualified barrels, store them in categories and mark them, and then deal with them uniformly.
2.2 Odour bucket: Clean it after picking it out, soak it in appropriate potion, soak it in activated carbon, hang a sign, confirm that it has no peculiar smell and pass the quality control inspection before use, otherwise it will be discarded.
2.3 Scratch bucket: pick it out individually, restore it, and check for water leakage. It can be put into use if it does not leak and the appearance inspection is qualified, otherwise it will be scrapped.
2.4 If the appearance is seriously dirty, it should be stored separately, marked with a sign, and cleaned with alkaline water. To remove foreign objects and moss in the dirty bucket, it should be cleaned separately and used after passing the test.
3. Prepare the “Process Pre-Inspection Record Form” every day
The second stage light inspection
1 Goal: This position is the last light inspection of empty barrels processing, and is a comprehensive inspection and evaluation of empty barrels processing to ensure that the qualified rate of empty barrels entering the internal washing machine is 100%.
2 assignments:
1) Visual and touch inspection
2) sniff
3) The external cleaning is clean and free of dirt, abnormality and discoloration
4) Labels and stickers are not damaged or peeled off
How to Clean the Outside of a 5 Gallon Empty Bucket
1. Objective requirements:
1.1 The outside of the barrel is clean and free of dirt, stains and different colors.
1.2 The labels and stickers are not damaged or fallen off.
2. Personnel hygiene requirements:
2.1 Employees should wear work clothes and employee ID cards before working, and wash their hands according to regulations.
2.2 The operation site is kept clean and hygienic.
3. Working standard:
3.1 Power on:
3.1 Before starting the machine, check whether the electricity and water of the equipment are normal.
3.2 Check whether the conveying chain is stable after the machine is turned on, and whether the washing machine pull-out chain (wheel) operates normally and whether the brush operates normally.
3.3 Preparation of cleaning solution
Alkaline cleaning solution is used for cleaning, which is prepared with tap water and edible alkali, and the concentration is 200PPM.
3.4 Check the cleaning pressure of the rinsing water to ensure that there is no residual alkaline cleaning solution. The rinsing water uses tap water and cannot be reused.
3.5 During the production process, the concentration of the cleaning solution and the pressure of the rinsing water should be checked frequently, and the investigation should be carried out in time.
4. Notes:
① On-site hygiene management
② Electrical safety
③ Whether there are unqualified buckets entering the washing machine
④ Qualified control barrel feeding speed
⑤ Check whether the water level of the water tank is normal in time to prevent water shortage
5. Possible bad points:
a. Spot check on the quality of the barrels (according to the requirements of sorting and inspection of barrels)
b. Pay attention to the concentration of alkali washing, and the pressure and position of the liquid level spray in time, and add or replace it in time
c. Spot check on cleaning effect
d. Equipment inspection and operation
e. On-site hygiene management
f. Personnel hygiene management
g. Correction and prevention report of abnormal quality
How to Clean and Disinfect 5 Gallon Buckets/Bottles and Caps
1. Bottle cap washing process
1.1 Process requirements
1) The cleaned cap must be a bottle cap for drinking water.
2) The bottle caps are first cleaned by hand with tap water, drained, and then placed in a disinfection tank, soaked in chlorine dioxide solution or peracetic acid disinfectant for more than 15 minutes, then taken out, sprayed with pure water for 5 minutes, and placed in the designated The concentration of disinfectant is shown in the attached table “Specification for Preparation of Cleaning and Disinfectant for Filling Lines”.
3) If the bottle cap is not used up after taking it out. After 1 hour, it needs to be sterilized again, and the sterilization procedure is the same as above.
4) After going to work every day, clean the disinfection tank and replace it with a reconstituted disinfectant. Check once every 2 hours, and add in time when the concentration is insufficient.
1.2 Inspection requirements
1) Visually confirm that it should be a special bottle cap for drinking water before cleaning.
2) Before entering the filling machine, the bottle caps should be soaked to deodorize the effect before entering the capping station.
3) Confirm that the concentration of the disinfectant and the soaking time meet the process requirements.
2. Bottle washing (barrel) process
2.1 PC bottle cleaning and disinfection process requirements
1) The cleaned and reused empty bottles or new bottles must be made of PC bottles for drinking water.
2) The reused bottle or new bottle is washed with alkaline water when entering the automatic cleaning machine. The cleaning time depends on the pollution of the bottle, and the cleaning is the standard.
3) After cleaning the inside and outside of the barrel with alkaline cleaning agent, rinse and disinfect with peracetic acid disinfectant. After cleaning and disinfection, the PC bottle is rinsed with purified water. The concentration of cleaning and disinfecting solution is shown in the attached table “Specifications for Cleaning and Disinfection of Filling Lines”.
4) Change the disinfection water every day, clean the water tank, filter screen, and clean the water spray pipe every week.
2.2 PET bottle cleaning and disinfection process requirements
After acceptance, the PET bottles are rinsed and disinfected with peracetic acid disinfectant, and the deodorization station is further rinsed and deodorized with pure drinking water. The concentration of disinfectant is shown in the attached table “Specifications for Cleaning and Disinfection of Filling Lines”.
2.3 Inspection requirements
1) Visually confirm that it should be a special bottle for drinking water before entering the bottle washer.
2) Visually inspect the cleaning quality one by one before entering the filling machine. The clean bottles should have no water traces and no visible pollutants, that is, the pre-inspection process.
3) Confirm that the concentration of the disinfectant meets the process requirements.
How to Operate Multimedia Filters
1. Description:
The multi-media filter is an important pretreatment device for the coarse filtration system. It uses homogeneous quartz sand and smokeless media as the filter material. Its function is to remove the suspended particles of agglomerated colloids and ensure that the water quality of the produced water meets the requirements of the reaction. The influent water quality requirements of the permeation device, and ensure that the effluent SDI (pollution index) is less than or equal to 5.
2. Precautions for use:
2.1 The multi-media filter has a controlled automatic timing backwash system. Generally, low-pressure backwashing for 20 minutes and positive flushing for 5 minutes starts at 8:00 every night. , to determine whether backwashing is necessary. When the pressure difference between the inlet and outlet of the filter is greater than 0.1MPa or the SDI value is greater than 5, the backwash of the multi-media filter should be carried out.
2.2 When making water, the sand filter pressure gauge should be less than 0.1MPa, and the equipment management personnel will be responsible for the management, and record the system conditions and operating parameters in order to analyze the system operation.
2.3 In order to stably maintain proper effluent quality, make the system operate effectively, and maintain the filter in good working condition, it should be done:
1) Check the inside of the filter at least once a year to ensure that there is no abnormality.
2) Replace the filter material every year or every two years.
3) If the filter is in the shutdown state, when the temperature is below zero degrees Celsius, anti-freezing measures must be taken, and the temperature should be kept above 5 °C.
How to run an activated carbon filter
1. Description:
The activated carbon filter is used as the pretreatment of the water treatment desalination system to absorb the residual chlorine that cannot be removed in the pre-filtration, which can effectively ensure the service life of the post-stage equipment, improve the quality of the effluent, and prevent pollution, especially to prevent the post-stage reverse osmosis. Membrane and other free state residual oxygen poisoning pollution. At the same time, it also adsorbs polluting substances such as small molecular organics leaked from the front stage, and has obvious adsorption and removal effects on odors, colloids, pigments, and heavy metal ions in water.
2. Precautions for use:
2.1 The activated carbon filter has a controlled automatic timing backwashing system. Generally, low-pressure backwashing starts at 9:00 every night for 30 minutes and positive flushing for 10 minutes. At the same time, there are pressure gauges before and after the filter. Determine whether backwashing is required. When the pressure difference between the inlet and outlet of the filter is greater than 0.1MPa, the backwash of the multi-media filter should be carried out.
2.2 When making water, the activated carbon pressure gauge should be less than 0.05MPa, and the equipment management personnel are assigned to be responsible for the management, and the system conditions and operating parameters are required to be recorded so as to analyze the system operation.
2.3 In order to stably maintain proper effluent quality, make the system operate effectively, and maintain the filter in good working condition, it should be done:
1) Check the inside of the filter at least once a year to ensure that there is no abnormality.
2) Replace the filter material every six months or every year.
3) If the filter is in the shutdown state, when the temperature is below zero degrees Celsius, anti-freezing measures must be taken, and the temperature should be kept above 5 °C.
How to operate the 5 micron security filter
1. Description:
The water treated by the pretreatment system passes through a 5-micron filter, which mainly removes the particles larger than 5 μm that pass through the multi-media filter and the activated carbon filter, and further protects the reverse osmosis system.
2. Precautions for use:
1) When the pressure drop at the inlet and outlet of the filter is greater than 0.1MPa, replace the filter element;
2) If it is used continuously for more than three months, replace the filter element.
How to Run a Reverse Osmosis Filtration
1. Description:
After being treated by a two-stage reverse osmosis system, 97% of dissolved solids, salts and ions can be removed from the water.
2. One stage reverse osmosis unit
2.1 The first-stage high-pressure pump is controlled by the following states:
2.1.1 Automatic
In the automatic state of the selection button of the field control cabinet, there are two starting methods:
a. Joint control of liquid level and time
① After the raw water pump is started for 5 seconds, the starting conditions of the high-pressure pump are satisfied.
② When the water level of the pure water tank (T-2) is below the high level, and after 12 o’clock in the evening, the high-pressure pump will start automatically. When the water level of the pure water tank reaches the high level, the original water pump will automatically stop.
2.1.2 Manual control
① When production water is needed during the day, press the start button on the central control cabinet to start the system, and when it needs to be stopped, press the stop button to stop the system.
② When the automatic system of the system fails, select the button on the field control cabinet to be in the manual state, and then press the manual start button to start the pump.
2.2 Notes:
1) Observe the flow meters of permeate and concentrated water, and adjust the RO concentrated water discharge valve to make the permeate volume reach more than 70%. Record the RO membrane inlet pressure, concentrated water pressure, and compare the pressure difference. If the pressure difference exceeds 4 kg under the same water supply conditions, please chemically clean the RO membrane.
2) Record the desalination rate of the RO membrane. If the desalination rate is lower than 97%, chemically clean the RO membrane.
3) Record the water production of RO. If the water production drops by 15% under the same conditions, the RO membrane needs to be chemically cleaned.
4) When the first stage RO pump is started, the pH probe of the permeate water will detect the pH value of the influent water and start the sodium hydroxide pump to keep the permeate water value between 8.2-9.2.
3. Secondary reverse osmosis unit
3.1 The first-stage high-pressure pump is controlled and operated by the following states:
3.1.1 Automatic
In the automatic state of the selection button of the field control cabinet, there are two starting methods:
Combined level and time control
① After 5 seconds after the primary high-pressure pump is started, the start-up conditions of the secondary high-pressure pump are met.
② When the water level of the pure water tank (T-2) is below the high level, and after 12 o’clock in the evening, the high-pressure pump will start automatically. When the water level of the pure water tank reaches the high level, the original water pump will automatically stop.
3.1.2 Manual control
When production water is needed during the day, press the start button on the central control cabinet to start the system, and when it needs to stop, press the stop button to stop the system.
When the secondary reverse osmosis high pressure pump is started, the pH probe before the pump will detect the pH value of the influent water. If it is lower than 6.0, the sodium hydroxide pump will start, and when it reaches 7.05, the sodium hydroxide pump will stop.
3.2 Notes:
1) Observe the flow meters of permeate water and concentrated water, and adjust the RO concentrated water discharge valve to make the permeate water reach more than 85%. Record the RO membrane inlet pressure, concentrated water pressure, and compare the pressure difference. If the pressure difference exceeds 4 kg under the same water supply conditions, chemical cleaning of the RO membrane is required.
2) Record the desalination rate of the RO membrane. If the desalination rate is lower than 97%, chemical cleaning of the RO membrane is required.
3) Record the water production of RO. If the water production drops by 15% under the same conditions, the RO membrane needs to be chemically cleaned.
4. Chemical cleaning of reverse osmosis (RO) systems
4.1 When one of the following situations occurs, chemical cleaning should be carried out
1) Under normal water supply conditions, when the pressure difference between the RO membrane inlet and outlet is greater than 4kg
2) Under normal water supply conditions, the water production decreases by 15%
3) The desalination rate is less than 97%
4.2 Preparation of cleaning solution
When the RO membrane is inorganic fouling and scaling, use acid cleaning
① Acid cleaning uses citric acid
② The cleaning water tank is 1000kg. After adding citric acid, it is made into an acidic cleaning solution with a pH greater than 2.
When the RO membrane is organically polluted, use alkali cleaning
① Alkaline cleaning uses sodium hydroxide
② Add sodium hydroxide to 1000kg of product water (1000kg of cleaning water tank) to prepare a cleaning solution with a pH greater than 8 and less than 12
4.3 Cleaning operation
1) Add a 5μm filter element to the cleaning filter
2) Prepare a suitable cleaning solution
3) The RO system is out of service. Close the RO water inlet valve, product water valve and liquid level valve, open the product water return valve and concentrated water return valve, and close the cleaning and discharge valve.
4) Close the outlet valve of the cleaning pump, open the cleaning circulation return valve, and start the cleaning pump.
5) Detect the pH value of the solution in the cleaning water tank.
6) When the pH of the cleaning water tank is stable and up to the standard, slowly open the outlet valve of the cleaning pump, inject the cleaning liquid into the RO system, and adjust the circulating return water valve so that the pressure of the RO membrane opening does not exceed 2.5kg
7) After the cleaning solution circulates in the RO membrane for 10 minutes, stop the operation of the cleaning pump, let the cleaning solution soak in the membrane for 30 minutes, and then turn on the cleaning pump to circulate. Repeat this. During the above operation, if the cleaning solution circulating back to the water tank is turbid and dirty, the cleaning solution should be drained, the cleaning solution should be reconstituted, and the chemical cleaning should be performed again. To no turbidity, dirt, foreign matter, particles.
8) After cleaning is completed, open the cleaning discharge valve. Drain cleaning fluid into waste line.
9) Fully open the RO inlet valve, open the raw water valve, and flush the RO membrane. Detect the pH of the effluent, and restore the valve to the normal operating state after it reaches the normal state. The system resumes normal operation.
How to run a 0.1 micron precision filter
1. Description:
The 0.1 micron precision filter is mainly used to remove particles larger than 0.1 μm in water to ensure the particle size requirements of the water point.
2. Notes:
1) When the pressure drop at the inlet and outlet of the filter is greater than 0.08MPa, replace the filter element;
2) If it is used continuously for more than six months, please replace the filter element.
1. Operation process:
1) Ventilation. Open the compressed air into the balloon valve to make the pressure close to 0.6Mpa/square centimeter, and then observe the current and voltage on the ozone machine.
2) The ozone generator is powered on. Turn on the low-voltage power supply (green button) of the ozone generator. At this time, the cooling fan of the machine should be observed to work, and after two minutes, an obvious smell of ozone should be smelled.
3) Open the pure water valve. Immediately after the ozone machine works, the pure water valve is opened to pour water into the oxidation tower. Pay attention to whether the valve positions of the oxidation tower are appropriate. Note that bubbles can be seen escaping upward from the oxidation tower microscope.
4) Shut down. When the water level reaches a certain height, close the pure water valve, cut off the power of the ozonator (red button), and turn off the oxygen valve (unscrew the pressure reducing valve screw counterclockwise).
2. Precautions for use
1) When the compressed air pressure is less than 2Mpa/square centimeter, do not continue to use it.
2) Water must be strictly prevented from flowing backwards from the oxidation tower to the ozonator.
3) When the cooling system fails, the yellow indicator light will be on and an alarm will sound.
4) The output pressure of ozone must not exceed 0.1Mpa.
The working current indicated by the ammeter should be very stable. If the working current indication changes greatly, the ozone generating unit may be damaged, so it should be shut down and repaired by professionals.
1. Precautions for use:
1) Before entering the filling workshop, the air purifier must be turned on for 30 minutes to make the air purification meet certain requirements.
2) The air shower (adjustable) must be turned on every time it enters the filling room, and it will be automatically turned off after 30 seconds.
3) Before filling, the empty car should be tested to confirm that everything is normal before the official operation.
4) The chlorine dioxide solution or peracetic acid disinfectant prepared in the disinfection tank should be replaced every day.
5) Keep the amount of flushing water at the drinking water station to ensure deodorization.
6) The suspended filling head must be immersed and disinfected with chlorine dioxide solution or peracetic acid disinfectant before filling. It is strictly forbidden to directly fill the unsterilized filling head.
7) Bottles and caps entering the empty bottle and bottle cap station must be cleaned and sterilized.
8) Operators must wear masks and disposable gloves, and it is strictly forbidden to directly touch the bottle neck and the inside of the bottle cap with their hands.
9) The filling machine must be filled in a sterilized and sealed room, and the air purification of the filling room as a whole reaches 1000 grades.
10) Closely monitor whether the number of filled bottles per hour meets the normal requirements. For the record, see “Light Inspection Record”.
11) For the preparation concentration of the disinfectant, see the “Production Line Cleaning and Disinfection Operation Standard”.
2. Inspection requirements
1) Monitor the amount of rinsing water for disinfection, sterilization, cleaning and deodorization to ensure the quality of work.
2) Light inspection to monitor whether there is any debris in the bottle after capping.
3) Monitor whether the number of bottles filled by the filling machine per hour meets the normal requirements
1. Purpose :
Standardize the work content of the finished product light inspection post, ensure product quality, improve equipment utilization efficiency, and reduce material loss.
2. Scope of application:
It is suitable for light inspection of products after filling.
3. Responsibilities
3.1 Light inspection: responsible for picking out unqualified products, responsible for checking the placement of heat-shrinkable film of barrels/bottles after filling; classifying and recording according to the inspection situation.
4. Assignment content
4.1 Before work
4.1.1 Turn on the conveyor belt and lubrication system.
4.1.2 Turn the power switch of the light inspection stand to ON.
4.1.3 Prepare the required shrink film.
4.1.4 Check the lamp inspection box to see if the lamp tube is abnormal. If there is any difference, the lamp must be replaced to ensure the brightness required for the inspection.
4.2 In production
4.2.1 The light inspection personnel should sit directly in front of the light inspection table, look at the light inspection table with both eyes, and place the bottled water 0.3-0.5 meters in front of the light inspection box (bottled water is placed at 0.01 meters).
4.2.2 When the product passes through the light box, wipe the water droplets on the surface of the bucket with a rag to make the sight of the surface of the bucket smooth. If the bucket mark is blocked and the sight is not good, turn the bucket to achieve the best viewing angle.
4.2.3 The light inspection shall meet the following standards:
A. Bottled water capacity: the level is above the first burr line below the bottleneck.
B. There is nothing visible to the naked eye in the container.
C. The water body is transparent and has no turbidity.
D. There is no obvious water leakage in the barrel.
4.2.4 After passing the lamp inspection, put on the heat shrinkable film, and place the unqualified products in the unqualified product area, and the production squad leader will handle it uniformly. If three barrels (10 bottles) of unqualified products appear continuously within 1 hour, report to the squad leader immediately to analyze the cause of the abnormality and take corresponding measures.
4.3 Each lamp inspection post counts foreign objects in the barrel, missing lids, crooked lids, irregular shrink films, etc., and records them in the “Finished Product Lamp Inspection Record”.
1. Process requirements
1) The plastic bag of the set must be a non-toxic, non-damaged and non-polluting transparent bag.
2) The surface of the finished bottle should be clean and free of pollution.
3) The bottle cap must be pressed tightly and sealed with a heat shrinkable plastic sleeve.
4) The packaging site should be disinfected by ultraviolet rays, and the ground should be clean and free of pollution.
5) When the finished bottle is poured into the plastic bag, prevent the sundries from being brought into the bag and pollute the finished bottle.
6) The mouth of the plastic bag must be fastened to prevent contamination during transportation.
7) The means of transport should be clean and hygienic; it should be handled with care, and it is strictly forbidden to throw, hit or squeeze.
8) Each finished bottle should be packaged with the corresponding product certificate.
2. Inspection requirements
1) There should be no debris pollution in the plastic bag after packaging.
2) The mouth of the plastic bag must be fastened, and the packaging bag should be intact.
3) The bottle cap is not loose, and the sealing heat shrinkable plastic sleeve must be intact and not damaged.
4) The production date of the product is in the form of coding, which should be clear and complete.
1. Purpose:
Standardize the requirements for the formulation, execution and monitoring of production processes to ensure that products that meet the requirements are produced under controlled conditions.
2. Scope of use:
It is suitable for the management of the company’s coding process operation.
3. Responsibilities:
The coding personnel strictly follow this procedure, and the quality control personnel supervise the implementation.
4. Procedure:
1) Before turning on the machine, check whether the locking screws of the machine are firm, and then clean the nozzle to make the ink jet smooth. First determine the coding position of the product, and then compile the coding format [in principle, compile six-digit date + time (minutes/24 hours) according to the normal production procedure], if the customer or product has special requirements, then according to the special requirements of the customer or product Requires the preparation of the coding format.
2) After the coding format is prepared, spray a few products to the production supervisor for confirmation. After the confirmation is passed, the production can be officially started.
3) During the coding process, the products that have been sprayed bad or the products that have not been sprayed should be selected, cleaned up and then sprayed. The selected non-conforming products will be placed separately and clearly marked, and will be dealt with uniformly.
4) The materials and products around the machine should be placed neatly to keep the aisle unobstructed.
5) Do a good job of cleaning and sanitation of machines and production sites before going off work.
5. Quality requirements:
The products with good coding must have the correct coding position and coding format, and the coding itself must be clear and complete. No blur, no word drop, no skew, no backsplash and no double code.
1. Check items before operation
1) Check whether the power supply is normal;
2) Check whether the chemicals in the barrel are sufficient, if not, replace it in time.
2. Boot operation
1. Power on: Turn on the main power switch in the control box, the “power display” light on the surface of the control box is on, and the system is powered on.
2. Add operation:
1) Addition for the first time: Refill the added amount of water after each time the medicine tank is emptied.
Operation: First turn the black knob to the “Add for the first time” gear, then press the green button for “Add for the first time”, the corresponding “button green indicator light” is on to indicate that it is being added, and when the light is off, it indicates that the addition has been completed. After First Add is complete, run Auto Add again.
2) Automatic addition: To reduce the concentration fluctuation of chemicals in the production process, when the “first addition” is completed, the “automatic addition” is turned on.
Operation: First turn the black knob to the “Auto Add” gear, then press the “Auto Add” green button, the corresponding “Button Green Indicator” is on, indicating that the automatic adding program is running, and the system will automatically add it regularly;
3) Manual addition: when the concentration of “automatic addition” is insufficient, use “manual addition” to supplement, and the manual addition amount is set to 1L each time;
Operation: First turn the black knob to the “manually add” gear, then press the “manually add” green button, the corresponding “button green indicator light” is on to indicate that it is being added, and when the light is off, it indicates that the addition has been completed. After Manual Add is complete, run Auto Add again.
product name | Sample size | sampling frequency | Judgment item | Eligibility criteria | judgement standard |
18.9 liters, 12 liter PC bottle | 10 (full inspection if the incoming batch is less than 10) | per batch | weight | 18.9L: Weight ≥750g/pc. 12 liters: weight ≥ 530 grams / piece | No more than 2 less than the standard, less than 2% of the weight is unqualified |
Exterior | It is colorless (or slightly blue) and transparent, and its transparency is close to that of ordinary flat white glass. No scratches, no obvious bubbles, no defects, the bottle mouth is neat, the thickness of the bottle wall is uniform, and there is no significant noise when squeezed by hand. | More than 2 discrepancies are considered unqualified | |||
Randomly sample 3 bottles from the same batch | Before the first delivery | Strength test | The bucket is filled with water and falls freely from a height of 2 meters, in good condition | If there is a damage, it is unqualified | |
18.9 liter bottle cap 12 liter bottle cap | 12 pcs | per batch | weight | 9.5g±0.3g | Less than 9.5g bottle cap more than 1 is unqualified |
Exterior | White and smooth, no black spots, no smudges, the inner plug seal is intact and no water leakage, the sealing film is completely printed and clear, and there is no peculiar smell. | Appearance unqualified more than 2 is the unqualified product | |||
tightness test | After capping, place the bucket horizontally and observe for 2 hours | More than 2 leaks are considered unqualified | |||
PET plastic bottles | 20 (from at least 3 minimum packaging units) | per batch | weight | 550ml: 14g±0.2g, | If the quantity of more than 5 pieces is insufficient, it will be considered unqualified. |
350ml: 14g±0.2g, | |||||
3 liters ≥ 85.0 grams | |||||
PET plastic bottle | 20 (from at least 3 minimum packaging units) | per batch | Exterior | The end surface of the bottle mouth is flat, the thread is smooth, there is no chipping, and there is no overflow. | Appearance of more than 3 discrepancies is considered unqualified |
first batch | strength | 1.8 meters full bottle falls to the ground without leakage | If there are 2 damages, it is not qualified | ||
per batch | bottle | Colorless, bright and transparent, no obvious defects, no scratches, no stains. | If there are 2 unqualified products, this batch is regarded as unqualified product | ||
Verticality | 150≤bottle height≤220mm, deviation≤3mm, | A deviation of more than 2 is considered unqualified | |||
Bottle height > 220 mm, deviation ≤ 4 mm | |||||
10 | tightness test | The finished product is placed vertically, squeezed by hand after half an hour, and there is no water leakage at the bottle mouth and bottom of the bottle | More than 2 leaks are considered unqualified | ||
first trial use | stacking test | After 30 days of stacking 8 layers (full bottles), the bottom layer should not have obvious deformation (6 layers of light bottles) | More than 10% deformation is unqualified | ||
PET plastic bottle cap | 30 pieces (from at least 3 minimum packing units) | per batch | weight | Order requirements ±5% | 2 weights are not enough to fail |
Exterior | Smooth, uniform color, round edges, smooth rib, no black spots, rust, oil, no obvious odor, no damage to the anti-theft ring. | 3 unqualified this batch is the unqualified product | |||
Geometry | 1. The limit deviation of external dimensions is ±0.20, and the limit deviation of internal dimensions is ±0.10. | A deviation of more than 2 is considered unqualified | |||
2. Randomly select 10 bottle caps from the incoming material. When the torque is greater than or equal to 180 degrees, the anti-theft ring will all be separated from the bottle cap. | |||||
15 bottles are randomly selected during the production process | tightness test | When the torque is greater than or equal to 30 degrees, and all the connection points of the anti-theft ring are not broken, squeeze it hard, and there must be no water leakage. | A deviation of more than 2 is considered unqualified | ||
PVC Shrink Film | 20 samples were randomly selected from each batch of 1000 mother samples | per batch | Geometry | Diameter 96-98 | More than 2 unqualified products are considered as unqualified products. |
Film thickness | more than 4 wires | Thickness between 3.5-3.9 can not exceed 3 sheets, thickness below 3.5 is not allowed to exceed 1 sheet | |||
Exterior | The text pattern is printed clearly and completely without wrinkling. | More than 1 is ineligible | |||
shrink effect | The shrinkage rate meets the needs of use, and the shrinkage is required to be uniform and tight, and there is no wrinkled skin at the upper seal. After cooling for 5 minutes, the shrink film does not move upwards after holding the object off the ground. | It is not allowed to have 1 unqualified, otherwise try 5 again, if there is still more than 1, it will be unqualified | |||
carton | 10 pcs | per batch | size | Meet the requirements when ordering | There is 1 unqualified product, this batch is the unqualified product |
Strength test | When the stack is full of 8 layers, the bottom layer will not be deformed | Obvious deformation is unqualified | |||
Exterior | The adhesion is neat and strong, the printing is clear, and there is no obvious color difference | 2 are unqualified | |||
Outer packaging bag | 15 pcs | per batch | size | Meet the requirements when ordering | If there are 2 unqualified products, this batch is regarded as unqualified product |
material strength | Meet the requirements for use | If there are 2 unqualified products, this batch is regarded as unqualified product | |||
Film thickness | More than 1.2 wire | There is a film thickness below 1 wire rejected, and 2 rejected between 1-1.2 wire |
Name | added substance | Addition/Concentration Requirements | Preparation quantity | Production Quantity (Bottles) |
(diluted to volume) | ||||
packaged drinking water | food grade potassium chloride | 60g/3.2mg/L | 80L | 1000 |
(18.9L) |
serial number | Product name | HKM Ultra Concentrated Alkaline Detergent Concentration | The concentration of HKM peracetic acid disinfectant (the original solution is calculated as 16.5%) is required to be 400±100mg/L (calculated as PAA) | |
Requirement 600mg/L (stock solution is calculated as 30.0%) | ||||
1 | 5 gallon line | morning | 1.2L | 1.53L |
afternoon | 0.6L | 727ml | ||
2 | 3 gallon line | 0.6L | 350ml | |
3 | bottled water line | —— | 160ml | |
4 | 3L Line | —— | 130ml | |
5 | Smart Cap Slot/PET Cap | —— | 945ml |
serial number | Product name | Dosage of HKM Ultra Concentrated Alkaline Detergent | Dosage of HKM Peracetic Acid Disinfectant |
(The stock solution is calculated as 30.0%) | (The stock solution is calculated as 16.5%) | ||
1 | 5 Gallon Line (1) | 1.08L [(600±100 )mg/L] | 1.3L [(400±100)mg/L(以PAA计)] |
2 | 5 Gallon Line (2) | 0.55L [(300±100)mg/L] | 1.3L [(400±100)mg/L(以PAA计)] |
3 | 5 Gallon Line (3) | / | 1.3L [(400±100)mg/L(以PAA计)] |
4 | smart cover slot | / | 150ml [550mg/L(以PAA计)] |
Area | Item | job name | frequency | Work requirements | operator | Check recorder |
Cleaning Workshop | washing tub | cleaning | Workshop supervisor | Empty the washing water, thoroughly clean the inside and outside of the tank with 1% alkali to ensure that the surface is clean and free of dirt, and rinse with water. | bottle washing post | Workshop supervisor |
5 gallon decapper | cleaning | Workshop supervisor | Thoroughly clean the inside and outside of the equipment with 1% alkali to ensure that it is clean and free of dirt, and the waste cover is cleaned out of the workshop. | cover post | Workshop supervisor | |
5 gallon bottle washing amchine | cleaning | Workshop supervisor | Thoroughly clean the inside and outside of the equipment with 1% alkali to ensure that it is clean and free of dirt, and the cleaning brush inside the machine is clean and free of oil stains. | bottle washing post | Workshop supervisor | |
Filling Workshop | 5 gallon bottle filling machine | cleaning, disinfection | Before each shift or 4 hours after production stops | 1. Clean and disinfect all water tanks once (clean with 600mg/L HKM ultra-concentrated alkaline detergent, disinfect with 550mg/L HKM peracetic acid disinfectant) and then rinse thoroughly with pure water. | 5 gallon filling post | Workshop supervisor |
2. Rinse the channel and filling head in the machine with pure water, spray 550mg/LHKM peracetic acid disinfectant for disinfection, and rinse thoroughly with pure water after 5 minutes. | ||||||
3. Thoroughly clean and disinfect the floors and walls once a week. | ||||||
small bottle filling machine | cleaning, disinfection | before production | The same as the operation requirements of automatic filling machine | small bottled water filling post | Workshop supervisor | |
Off-board water tank | cleaning, disinfection | per month | First wash with 1% hot alkaline water, then disinfect with 550mg/LHKM peracetic acid disinfectant, and then rinse thoroughly with pure water. | 5 gallon filling post | Workshop supervisor | |
Ozone mixed water tower | disinfect | per month | Disinfect with 550mg/LHKM peracetic acid disinfectant, and then rinse thoroughly with pure water. | 5 gallon filling post | Workshop supervisor | |
Whole workshop | One and two wash basins | cleaning, disinfection | every day | Check soap and sanitizer, ensure use, wash and disinfect hand basins. | cleaning post | Workshop supervisor |
indoor air | disinfect | weekly | Air disinfection was performed with 0.3 ppm ozone. | 5 gallon filling post | Workshop supervisor | |
Indoor walls, ceilings, exposed pipes | cleaning, disinfection | weekly | First wash with 1% hot alkaline water, then scrub and disinfect with 550mg/LHKM peracetic acid disinfectant, and then rinse thoroughly with pure water. | each team | Workshop supervisor | |
indoor floor, | cleaning, disinfection | every day | First wash with 1% hot alkaline water, then scrub and disinfect with 550mg/LHKM peracetic acid disinfectant, and then rinse thoroughly with pure water. | each team | Workshop supervisor | |
Pure water pipeline | cleaning, disinfection | Per year | Soak in hydrogen peroxide for 24 hours, then rinse thoroughly | company unity | Workshop supervisor |
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