If you want to start a bottled water business,equipment costs are among the most important factors you need to consider. The types of equipment and production capacity you choose will determine your total investment needed.
This guide covers bottled water business startup costs and the major equipment required to produce 3,000 bottles of 500 ml bottled water per hour. We’ll break down:
• The total equipment investment range needed ($240k – $260k)
• Key systems like water treatment, bottle blowing and filling lines
• Other costs beyond equipment
• Things to consider for your specific needs
Armed with this information, you’ll be able to make more informed decisions on equipment selection, funding requirements and your bottled water production goals.
The four main equipment categories needed are:
Water Treatment System
This purifies source water to the required level of purity for bottling.Bottle Blowing Machine
This shapes preforms into bottles at high speed.Filling Line
This fills, caps and packages the finished bottles.Auxiliary Equipment
Items like shipping containers, compressors, conveyors and more.
By understanding the investment needed for each stage of equipment and other costs involved, you’ll have a clearer picture of the budget required to start your own bottled water business making 3,000 bottles per hour.
The table below provides a breakdown of the estimated costs for the major equipment needed to produce 3,000 bottles of 500ml bottled water per hour:
| Equipment | Estimated Cost |
|---|---|
| Water Treatment System | $22,000 |
| Bottle Blowing Machine | $90,000 |
| Filling Line | $120,000 |
| Other Costs | $15,000 – $30,000 |
| Total Equipment Cost | $247,000 – $262,000 |
Note: The estimated costs for “Other Costs” includes shipping, electricity, labor, and materials. These costs are rough estimates and may vary depending on several factors. Additionally, the total equipment cost is based on the estimates provided in the article and may differ based on specific system requirements, brand, supplier, and negotiations.
01.
Water treatment: 2 tons of single-stage RO water treatment: starting cost is about US$22,000, 15Kw.
General information
If you’re in need of water filtration, our comprehensive system usually includes a raw water tank, pure water tank, quartz sand filtration, activated carbon filtration, precision filtration, 1 stage RO reverse osmosis filtration, Ozone system, and UV disinfection system. Our desalination rate is an impressive 97%, and after filtration, water quality can reach 400ppm.
Our single-stage reverse osmosis equipment is ideal for areas where the conductivity of raw water is less than 300μs/cm. However, for regions exceeding 300μs/cm, our two-stage reverse osmosis equipment is required to produce pure water that meets national standards, boasting a conductivity ≤10μs/cm. Trust us to provide you with the cleanest and purest water possible.
Equipment included
- Raw water tank
- Multi-media filter
- Activated carbon filter
- Cationic resin softener
- Precision filter
- High-pressure pump
- Reverse osmosis system
- Ozone sterilization system
- Pure water tank
Technology details
- First-Level Pretreatment System
Our quartz sand multi-media filter effectively removes harmful particles above 20UM in size, including silt, manganese, rust, colloidal substances, mechanical impurities, and suspended solids, all of which can be harmful to the human body. Our automatic filtration system uses an imported Fleck controller, which carries out a series of backwashing and forward washing procedures, making maintenance easy and keeping operating costs low. Our filtration media includes PPF, AC coconut carbon, and other high-quality materials.
- Second-Level Pretreatment System
Our activated carbon filter removes pigments, peculiar smells, and large amounts of biochemical organic matter from water. It also reduces residual chlorine values and eliminates pesticide pollution and other harmful pollutants. Our advanced automatic filtration system uses an imported Fleck controller that allows for efficient backwashing and forward washing.
- Third-Stage Pretreatment System
Our cationic resin is used to soften water by eliminating hardness, primarily composed of calcium (Ca2+) and magnesium (Mg2+) ions. As raw water passes through the resin layer, the Ca2+ and Mg2+ are exchanged and absorbed by the resin, releasing sodium and Na+ ions at the same time. The resulting water is softened water free from hardness ions, preventing scale buildup on our reverse osmosis membrane. Our system can automatically carry out recoil, front flush, and intelligent resin regeneration to ensure maximum efficiency and extend service life.
- Fourth-Stage Pretreatment System
Our precision filter has a 5-micron pore size, ensuring optimal color and turbidity for purified water. This filter guarantees the RO system meets all water inlet requirements.
- RO Pure Water Equipment Host System
Our reverse osmosis technology desalinates water efficiently. The reverse osmosis membrane pore size is only 0.0001 micron, effectively removing harmful soluble solids, bacteria, viruses, and more, offering a desalination rate of over 99.6%, producing pure water that meets national standards. Our high-pressure pump and reverse osmosis membrane are the core equipment of the system, which provides sufficient pressure for the reverse osmosis membrane element to overcome osmotic pressure, meeting the device’s rated water output.
- Ozone Sterilization System
Our ozone sterilization system uses a powerful oxidizing agent to provide four primary functions: sterilization, oxidation, decolorization, and deodorization. At a concentration of 4mg/L, our ozone system kills all bacteria in 0.5-1 minute. Additionally, our system ensures fresh, oxygen-rich water that maintains its water activity without any impurities.
02.
Blow Molding Machine: 3000BPH x A4: Starting cost is about US$90,000, 60Kw
Equipment included
A blow molding machine, also known as a bottle blowing machine, is equipment that blows preforms into PET bottles. We offer an automatic blow molding machine with a capacity of 3,000 bottles per hour (BPH) that uses the latest technologies to produce high-quality, custom PET bottles for your bottled water products.
The bottle blowing process has two stages:1. Preform Heating: Infrared lamps radiate and heat the preform to soften the body. The neck remains unheated.2. Bottle Blow Molding: The heated preform is placed into a bottle mold. High-pressure air inflates the preform body into the mold, shaping it into a custom PET bottle. Our automatic machine smoothly combines preform heating and bottle blow molding to efficiently produce PET bottles at high speed while eliminating excess human contact. Precision temperature controls and molds also ensure high quality, consistency and customization of your bottled water bottles.Please contact us for a quote and specs on a blow molding machine for your bottled water plant
Includes:
- Bottle Blowing Machine: Blows preforms into PET bottles.
- Preform Heater: Infrared lamps heat and soften the preform body.
- Cooling Device: Cools the preform neck to retain its shape.
- High/Low-Pressure Air Compressors: Provides the pressure to inflate preforms.
- Water Chiller: Cools the equipment.
- Air Dryer/Filter/Tank: Processes the air for bottle blowing.
- Bottle Molds: Give preforms the custom bottle shape.
Workflow
Workflow: Understanding the Bottle Blowing Machine Process
A bottle blowing machine is a specialized device that utilizes advanced technology to transform finished preforms into bottles. This process consists of two main stages – preheating the preforms and bottle blow molding.
- Preheat of Preforms:
To begin, an infrared high-temperature lamp is used to irradiate the preform. This action heats and softens the body of the preform, which is essential for the subsequent process. However, the neck of the preform does not require heating to maintain its shape. Therefore, a specific cooling device is used to cool it down.
- Bottle Blow Moulding:
Once the preform has been adequately heated, it is placed in a blow mould. Here, the preform is inflated with high-pressure air, pulling and shaping it into the desired bottle shape.
- Automated Bottle Blowing:
With the help of manipulators, the automatic bottle blowing machine combines the two critical operations of preheating the preform and bottle blow moulding. This eliminates the need for manual intervention to put the preheated preform into the mould, thereby significantly improving production rates.
In summary, understanding the workflow of a bottle blowing machine is crucial in optimizing the bottle manufacturing process. By streamlining the preheating and molding stages, production rates are increased, and the quality of the final product is improved.
03.
Next is the filling line, the starting cost is about US$120,000, 55Kw
If you are planning to start a beverage bottling business, the filling line is a crucial investment for your success. The starting cost for the filling line is around US$60,000 and requires 55kW power. The line includes essential equipment such as a bottlecap sterilizer, filling machine, bottlecap capping machine, blow dryer, laser code printer, sleeve labelling machine, shrink film wrapping machine, and 20-meter conveyor system.
Equipment included
- Bottle cap sterilizer,
- Monobloc filling machine,
- Bottle cap feeding machine
- blow dryer,
- Laser code printer,
- Sleeve labelling machine
- Shrink film wrapping machine,
- and 20-meter conveyor system
Technology details
Filling Machine: Precisely Filling Bottles at High Speed
The water filling machine is the core equipment in the bottled water production line. Our 3-in-1 monobloc rinser/filler/capper integrates advanced technologies to quickly and accurately fill and cap PET bottles.
- It incorporates bottle rinsing, filling and capping systems in a single compact machine. This simplifies operations, reduces floorspace requirements and lowers costs versus separate machines.
- The bottle washer is a 8-head rotary rinser that clamps bottles and rinses the interiors using sterile water jets. Bottles are inverted for complete draining before proceeding to the filling system.
- The filling system uses an advanced volumetric piston filler with 8 filling heads and nozzles to fill bottles precisely to the target volume at high speed. Fill levels are electronically controlled and monitored to minimize product loss/waste and ensure consistent fills.
- The capping system consists of 3 capping heads that apply caps onto the bottle openings. Capping chucks grip the caps and spin them onto the bottles at a specified torque for proper sealing. Caps are then checked to verify secure application before bottle release.
- Italian technologies incorporated into the filler allow for faster filling speeds while achieving precise volumetrics. This results in high productivity and an efficient bottling operation.
- Advanced automation with servo motors, PLC controls and instrumentation precisely coordinates the sequences of clamping, rinsing, filling, capping and bottle release. Minimal human intervention is required.
- Nozzle and chuck designs are customized for your specific bottle types and sizes. Filler can handle a variety of bottle shapes, openings and volumes.
- Stainless steel construction and sanitary design allow for thorough cleaning and sanitation procedures to prevent product contamination.
Our monobloc fillers produce 3,000 to 4,000 bottles per hour consistently and cost-effectively while achieving high quality and fill accuracy for your bottled water products. Please contact us for a quote and details on the technologies and options we provide for your bottling line.
Cap Elevator Machine: Feeding Caps into the Filling Line
The cap elevator machine is equipment that feeds bottle caps from the cap hopper into the capping system of the filling line.
It includes:
- Cap Hopper: Stores a large volume of caps and feeds them into the elevating mechanism. Hopper is sized based on your production capacity and changeover frequency.
- Elevator Belt: Endless conveyor belt with attachments that pick up caps from the hopper and elevate them up and into the filler/capper machine. The inclined belt uses cleats or recesses to grip the caps securely during elevation.
- Cap Chute: Guides the caps coming off the top of the elevator belt into the capping system of the filler/capper. The chute also helps regulate the cap flow into the machine to match its capping speed.
The cap elevator provides a steady supply of caps into your filler/capper to maximize its productivity and minimize downtime waiting for caps. All parts in contact with caps are constructed of stainless steel for compatibility with your product and cleanability.
Cap Sanitizing Machine: Disinfecting Bottle Caps
The cap sanitizing machine disinfects bottle caps before capping to prevent contamination of your bottled water products.
It consists of:
- Cap Discharge System: Receives caps from the cap elevator or hopper and discharges them into the sanitizing tunnel. Uses a vibratory plate to spread caps evenly into the tunnel.
- Sanitizing Tunnel: Stainless steel chamber where caps are sprayed with a disinfecting agent, typically ozonated water or hydrogen peroxide. Multiple spray nozzles direct sanitizer over all surfaces of the caps as they pass through the tunnel.
- Disinfectant Dosing System: Adds a controlled amount of disinfectant concentrate into the sanitizer water to achieve proper disinfection concentrations. Concentrations are monitored to ensure caps are fully sanitized.
- Sanitizer Water Circulation System: Pumps sanitizer water through the spray nozzles which then drains back to a collection tank for recirculation. Water is filtered and cooled for maximum effectiveness.
The cap sanitizing equipment provides a critical safeguard to protect your bottled water quality and ensure the highest standards of hygiene. Fully sanitized caps reduce the risk of spoilage or contamination issues from improperly disinfected closures.
Bottle Dryer: Drying Bottles After Filling and Sanitizing
The bottle dryer uses forced hot air to thoroughly dry the exterior of filled bottles. This ensures an effective, high-quality application of labels in the next stage of production.
- Stainless steel enclosed housing contains multiple air knives or nozzles to direct heated air over all surfaces of bottles. Air temperature, flow rate and number of nozzles are customized to your bottle size and material.
- Bottle infeed and discharge systems, often starwheels, index bottles into and out of the dryer enclosure. Bottles pause under the air flow for several seconds to ensure complete drying before being discharged.
- Air heating system uses electric or steam coils to heat ambient air to the target temperature, usually 50 to 70°C for PET bottles. Temperatures are controlled and monitored to avoid overheating bottles.
– Recirculating air flow design pulls air from inside the enclosure and re-directs it over the heating coils before blowing it back onto the bottles. This pre-heats the air for maximum efficiency and effectiveness. A portion of damp air is exhausted and replaced. - Bottle rotation during drying (Optional): Bottle grippers or supports within the enclosure can mechanically rotate or spin bottles under the air flow. This exposes all surfaces to the heated air stream and improves drying uniformity, especially inside bottle bases or handles.
- Safety controls: Over-temperature protection, low airflow monitoring and other controls prevent damage to bottles in case of system malfunctions.
A well-designed bottle dryer, with customizable options for your container type, improves labelling quality and efficiency in your bottled water processing line. Thoroughly dried bottles provide an ideal surface for label adhesion. Please contact us to determine an effective, affordable drying solution to suit your production.
Laser Code Printer: Printing Traceability Codes on Bottles and Caps
The laser code printer uses a laser to mark production codes directly onto bottles, caps or product labels for traceability.
Details include:
- Compact stainless steel enclosure contains a CO2 or fiber laser marking system. The laser generates intense focused light beams to alter the surface of plastics like PET, creating permanent marks.
- Bottle/cap infeed system conveys containers into the laser enclosure for coding. Products pause briefly under the laser marking area before being discharged. Product guides ensure consistent positioning for clear, accurate code placement.
- Touch screen control panel allows an operator to easily enter the required traceability codes including production date, time, lot number, line number, etc. The code sequence is downloaded to the laser system for marking.
- The laser head focuses beams onto bottles/caps according to the programmed code. Precise beam control allows marking of text, numbers, logos and barcodes. Beam intensity is closely controlled to create clear marks without damaging the plastic.
- Fume/particle extraction system removes any emissions generated during laser marking to provide a safe operating environment. Extracted air is filtered before exhausting outside the facility.
Laser coding is a non-contact, permanent method of printing traceability codes for product identification and recall. It eliminates issues like smudging, tearing or fading experienced with traditional contact coders like inkjet printers.
Please contact us to discuss laser coding options for your bottled water products. We can provide a system tailored to your production needs, types of containers and quality requirements. Automation levels vary depending on your budget and line integration.
Transportation and Other Requirements
Shipping: The bottled water production equipment described requires approximately 2 x 40’ high cube shipping containers for delivery. This includes the blow molder, filling line and all auxiliary equipment.
Power: The equipment system requires an estimated 130kW of power to operate. 3 to 5 workers are needed concurrently to monitor, control and maintain the various machines.
Workspace: 100 to 200 square meters of plant floorspace is necessary to situate the blow molding machine, filling line, storage areas and worker access around the equipment. Precise space requirements depend on your selected equipment options.
Raw Materials: 25/30mm preforms and matching caps are required, costing approximately US$0.04 per bottle set. Preform and cap styles must suit your selected bottle design. Additional PET resin, labels, trays, film and other materials also need to be sourced.
Service Life and Depreciation: The bottled water production equipment has an estimated useful life of 10 years with proper operation and maintenance. An average depreciation rate of 10% per year can be expected due to the mix of mechanical equipment, controls and automation built into the system.
Additional requirements include:
– Compressed air for pneumatic components and controls at 6 bar
– Chilled water for cooling blow molds, filling valves and other equipment
– Product inlet and outlet piping for water treatment, filling and cleaning systems
– Electrical wiring to control panels, motors, heaters and instrumentation
– Drainage for waste, overflow and cleaning runoff
– Ventilation for any fumes or excess heat generated
– Space for spare parts storage
– Facilities for employee breaks, changing, bathrooms, etc.
The additional infrastructure, utilities, raw materials and workspace surrounding your bottled water production equipment are important to consider in your plant layout, budgeting and startup costs. Please contact us for guidance on fully equipping your bottled water facility. We can provide recommendations and estimates for ancillary equipment, installation and other requirements to complement your PET bottling line.
04.
Transportation and others
Transportation and Other Requirements
Shipping: The bottled water production equipment described requires approximately 2 x 40’ high cube shipping containers for delivery. This includes the blow molder, filling line and all auxiliary equipment.
Power: The equipment system requires an estimated 130kW of power to operate.
Workers: 3 to 5 workers are needed concurrently to monitor, control and maintain the various machines.
Workspace: 100 to 200 square meters of plant floorspace is necessary to situate the blow molding machine, filling line, storage areas and worker access around the equipment. Precise space requirements depend on your selected equipment options.
Raw Materials: 25/30mm preforms and matching caps are required, costing approximately US$0.04 per bottle set. Preform and cap styles must suit your selected bottle design. Additional PET resin, labels, trays, film and other materials also need to be sourced.
Service Life and Depreciation: The bottled water production equipment has an estimated useful life of 10 years with proper operation and maintenance. An average depreciation rate of 10% per year can be expected due to the mix of mechanical equipment, controls and automation built into the system.
Additional requirements include:
– Compressed air for pneumatic components and controls at 6 bar
– Chilled water for cooling blow molds, filling valves and other equipment
– Product inlet and outlet piping for water treatment, filling and cleaning systems
– Electrical wiring to control panels, motors, heaters and instrumentation
– Drainage for waste, overflow and cleaning runoff
– Ventilation for any fumes or excess heat generated
– Space for spare parts storage
– Facilities for employee breaks, changing, bathrooms, etc.
The additional infrastructure, utilities, raw materials and workspace surrounding your bottled water production equipment are important to consider in your plant layout, budgeting and startup costs. Please contact us for guidance on fully equipping your bottled water facility. We can provide recommendations and estimates for ancillary equipment, installation and other requirements to complement your PET bottling line.
Please click below to watch the production process of bottled water production.
