Dedicating in designing and implementing tailored made complete PET bottled water filling machine solutions for water, your production targets will be easily reached with our help. Moreover, by retaining the bottle’s durability and expanding design opportunities we’ve greatly reduced the weight of water bottles, thereby minimizing production costs in the water bottler production line.
Steplead certified parts with additional warranty
Less energy using lower engine speed and larger hydraulic pump.
Bottled water continues to be one of the most valuable beverages in the world. A smarter solution is needed to meet the high demand while maintaining the flexibility needed to meet various beverage market preferences.
The Steplead rinsing solution of water filling machine integrates all the process steps with improved ergonomics.
Hygienic design and complete transparency ensure the highest food safety standards always meet in beverage production.
Highly flexible product filling functionality in an all-in-one solution of water filling machine for optimal performance
Fastest single file accumulation speed from 1,000 to 40,000 bottles per hour
Intelligent bottle filling processing principles are combined with proven logical motion filling technology.
To achieve the most efficient bottling line production, Steplead professional in manufacturing innovative, versatile, and trustable capping solutions for any specific demand and capacity requirement from clients. With Steplead capping equipment, customers can easily apply closures to virtually any rigid package on the beverage market.
|Capacity based on 500ml PET bottle||4000BPH||6000BPH||10000BPH||12000BPH||18000BPH|
|Suitable bottle shape||PET bottles with different volume and shapes|
|Suitable bottle diameter(mm)||Φ50-115|
|Suitable bottle height||160-320mm|
|Compressed air pressure||0.3-0.7MPa|
|Washing water pressure||＞0.06MPa,≤0.2MPa|
|Motor power (KW)||2.2||3.5||4.5||6||7.5|
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Installation of machines and equipment or filling line at the factory of customer.
Synchronize and coordinate schedule with engineering to proceed switches and preventive maintenance operation.
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The main materials used in our beverage equipment are food grade SUS304, SUS316, POM and silicone parts that meet sanitary standards, as well as world-renowned electrical components. We can also make any custom design for you according to your needs.
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Here is a list of all the types of technical questions concerning bottle filling machine that you can find.
Because liquid materials have varied physical and chemical characteristics, they require different filling procedures. The fluid storage device (usually called the liquid storage tank) receives the liquid material and fills it into the packaging container. The following techniques are frequently employed to finish this operation.
1.Atmospheric filling method
Atmospheric pressure filling is to directly rely on the weight of the filled liquid to flow into the packaging container under atmospheric pressure. The machine that serves the liquid product into the packaging container under normal pressure is called the normal pressure filling machine.
The process of atmospheric filling is:
①Inlet and exhaust, that is, when the liquid enters the container, the air in the container is exhausted at the same time;
②Stop the liquid feed, that is, when the liquid material in the container reaches the quantitative requirement, the liquid feed will automatically stop;
③Removing the remaining liquid, that is, removing the remaining liquid in the exhaust pipe. This process is necessary for those structures that exhaust to the upper air chamber of the liquid storage tank.
The atmospheric pressure method is mainly used for filling low-viscosity and non-gas liquid materials, such as milk, white wine, soy sauce, medicine, still water or pure water etc.
The liquid storage tank’s top air chamber is used to inflate the package, which causes the pressures of the two chambers to be nearly equal. The material is then forced into the container by its own weight because it has been inflated with compressed air from the upper air chamber. An Isobaric filling machine is a device that uses an equal pressure filling technique.
The process of equal pressure filling is:
①Inflation and isobaric;
②Inlet liquid and return air;
③Stop the liquid supply;
④To avoid a large amount of bubbling, after all the air has been released, release the pressure trapped in the bottle’s bottleneck to the atmosphere, avoiding a sudden drop in pressure that might cause a lot of bubbling and affecting packaging quality and accuracy.
The isobaric method is suitable for filling gas-containing beverages, such as beer, soda, etc., to reduce the loss of the gas (CO₂) contained therein.
At low pressure, the liquid filling is done while the chamber is under atmospheric pressure. It has two methods: one that uses differential pressure to maintain the interior of the liquid storage tank at an average pressure and only draws air into the packaging container to create a certain degree of vacuum, and another that does just that. The liquid material is transferred from the container into the package after the pressure difference between them has been eliminated; it’s a gravity vacuum type. As a result, the liquid storage tank and packaging container are in an almost equal vacuum condition. The liquid material enters the container by its own weight. A machine that uses a vacuum filling technique is known as a vacuum filling machine.
The process of vacuum filling is:
①The bottle is empty;
②Inlet and exhaust;
③Stop the liquid supply;
④Reflow of residual liquid, that is, the residual liquid in the exhaust pipe flows back into the liquid storage tank through the vacuum chamber.
The vacuum method is suitable for filling liquid materials with higher viscosity (such as oils, syrups, etc.), liquid materials containing vitamins (such as vegetable juice, fruit juice, etc.) and toxic liquid materials (such as pesticides, etc.). This method can increase the filling speed and reduce the contact and effect of the liquid material with the remaining air in the container, so it is beneficial to prolong the shelf life of certain products. In addition, it can also limit the escape of toxic gases and liquids, thereby improving the operation Conditions. Still, it is not suitable for filling wines containing aromatic gas because it will increase the loss of wine aroma.
4.Pressure method filling
Pressure filling is to control the reciprocating movement of the piston with the help of mechanical or pneumatic hydraulic devices and suck the liquid material with higher viscosity from the storage cylinder into the piston cylinder, and then force it into the container to be filled. This method is sometimes also used for serving soft drinks such as soda. Since it does not contain colloidal substances, the foam is easy to disappear. It can be directly poured into the bottle without pre-inflation by relying on its strength, thereby significantly improving Filling speed.
The siphon filling method applies the siphon principle to make the liquid material sucked into the container from the liquid storage tank through the siphon tube until the liquid level of the two is equal. This method is suitable for filling low-viscosity and air-free liquid materials with simple structure but low filling speed.
Classification of packaging containers
1. Classified by material:
2. According to hardness:
Any container made of metal, glass, ceramic or plastic that can withstand 15 pounds of downward pressure without deforming and that does not leak liquid after being sealed is called a rigid container.
Any container made of lightweight plastic (usually blow-moulded or thermoformed) or cardboard and its composite paper and sealed with a lid that does not leak liquid is called a semi-rigid container.
Any container made of plastic film, metal foil, plastic composite film, or composites is called a non-rigid container.
Liquid product classification
Liquid products can be divided into:
Any liquid that can flow through the tube at a certain speed under its own gravity is called fluid. The flow rate is mainly affected by fluid viscosity and pressure, and the general viscosity range is specified as 1~100 centipoise.
A liquid that can flow in a round tube under pressure greater than its own gravity is a semifluid. Its viscosity ranges from 100 to 10,000 centipoise.
3. Viscous fluid:
If the product viscosity exceeds 10,000 centipoises, it does not belong to the range of fluid and semifluid.
4. For low-viscosity liquid materials, according to whether the liquid contains carbon dioxide gas,
it can be divided into
5. Whether it contains alcohol or not
It can be divided into
Filling machine classification
According to the conveying form of the packaging container, it can be divided into the following types.
When filling, the packaging container moves linearly and intermittently from one station to another station. The machine that completes the filling when it is stopped is called a linear filling machine.
Simple structure and convenient manufacturing
Relatively large area
Difficulty in improving production capacity
Generally only used for filling of non-gas liquids.
After the packaging container enters the filling station, this type of filling machine rotates around the worktable for one round. It performs a constant speed rotation to complete the filling. The structure of the rotary filling machine is shown in Figure 3-1.
Widely used in the food and beverage industry.
1. Bottle conveying device.
2. Bottle feeding wheel
3. Lifting mechanism
4. Fixed cover
5. Middle dial wheel
6. Gland dial wheel
7. Bottle out dial wheel
8. Annular reservoir
9. Vacuum channel
10. Filling valve
11. Rotary distributor
3) Aseptic filling machine
Tetra Pak filling equipment is commonly used for filling juice and milk. It is filling equipment for the flexible packaging of composite paper. The filling capacity is 0.25L ~ 2L, and it has brick shape, gable top and triangle.
In daily life, liquids to be commercialized packaging involve many fields and a wide range. There are various packaging containers, and the packaging capacity ranges from tens of millilitres to hundreds of litres. Liquid filling machinery is mainly designed for three packaging containers: glass bottles, cans, and PET bottles.
In addition to the types of filling machines listed above, the manufacturer can also produce filling machines designed according to customers’ unique needs, special packaging containers, and special products (such as high-viscosity products).
In many cases, there are several types of filling machines for the packaging of a liquid.
A simple classification of various filling equipment common in the food industry (including some chemical industries) and whose filling capacity is the most 150mL~2000mL are listed in Table 3-1.
|Classification||Filling machine model||Main feature|
|Classified by filling principle||Isobaric filling machine||Used for the packaging of beer, carbonated drinks and other carbonated beverages, and can also be used for filling non-gas beverages|
|Negative pressure filling machine||It is used for the filling of non-gas beverages and wines, and the filling valve has very little leakage.|
|Atmospheric filling machine||Volume fixed olefin, gravity filling. It is used for filling wine, dairy products, condiments, mineral oil, medicines, health products and other fruits and flowers, with very small liquid loss|
|Pressure filling machine||It is used for the filling of non-gas, high-viscosity beverages and semi-fluid, with a fast filling speed and no liquid loss|
|Classified according to the arrangement of filling valves||Linear filling machine||Intermediate step-by-step transportation, suitable for special-shaped packaging containers, large-volume liquid packaging, and low production efficiency|
|Rotary filling machine||There is a universal filling structure developed by a linear filling machine, which can work continuously at high speed and the productivity of the equipment is high.|
|Tin foil heat sealing/plastic||Packaging of dairy beverages, compound sealing method|
|Cap screw-sealing filling machine|
Filling quantitative method
1. Quantitative Method for Controlling Liquid Level Height
The purpose of a quantitative filling is achieved by controlling the height of the liquid level in the filled container.
a) before filling; b) during filling; c) after filling
1. Exhaust pipe; 2. Filling rack; 3. Nut; 4. Spring; 5. Sliding sleeve; 6. Rubber pad; 7. Filling head; 8. Compression nut; 9. Adjusting nut; 10. Reservoir; 11. Bottle
2. Quantitative Cup Quantitative Method
The liquid is first injected into the quantitative cup for quantitative measurement. Then the measured liquid is injected into the bottle to be filled. The volume of each filling is equal to the volume of the quantitative cup.
a) before filling b) after filling
1-Dosing cup; 2-Dosing adjustment tube; 3-valve body; 4-fastening nut; 5-seal; 6-inlet pipe; 7-spring; 8-filling head; 9-vent hole; 10-lower hole; 11-Separator; 12-Upper hole; 13-Intermediate tank; 14-Liquid storage tank
Schematic diagram of cock type dosing cup type dosing mechanism
1. Thin tube; 2 dosing cup; 3. Three-way stopcock; 4. Inlet tube; 5 filling nozzle
3. Quantitative pump quantitative method
1- Storage tank
The structure of the bottle filling machine
At present, most filling machines adopt a rotating structure; that is, the packaging container rotates at a constant speed along with the filling valve, and the filling is carried out simultaneously. The number of filling valves in each filling machine is called the filling head number of the filling machine. The structure of the rotary filling machine is more complicated.
Figure 3-1 shows the structure diagram of the TVF rotary filling machine.
The liquid material enters the annular liquid storage tank 8 by the rotary distributor 11. The bottle is sent to the bottle lifting mechanism 3 by the bottle conveying device 1, the bottle feeding wheel 2, and the bottle rotates around the filling machine while rising. When it is in close contact with the filling valve 10, the liquid material is automatically filled. After the filling is completed, it is sent to the horizontal position by the lifting mechanism 3 and then sent to the capping machine by the middle dial wheel 5. Whenever the filling machine is finished, it can be cleaned automatically.
1. Feeding device for packaging container (bottle)
In the automatic filling machine, according to the filling process requirements, accurately feeding the container to be filled onto the bottle table of the primary turntable lifting mechanism is the key to ensuring the regular and orderly operation of the filling machine. The critical problem of the general supply mechanism is the continuous transportation of containers and the timing supply of containers. Commonly used feeding devices include screw, conveyor chain and star wheel. Figure 3-2 shows a schematic diagram of a typical container feeding mechanism.
Schematic diagram of bottle conveying structure
1. Wave speed reducer; 2. Split conveyor screw; 3. Double-layer arc guide plate; 4. Conveyor chain plate; 5. Double-layer star wheel; 6 Translation induction guide plate
1) Screw type feeding device
This device can complete the actions of increasing, decreasing, diverting, lifting and turning over regular or irregularly arranged batches of packaging containers according to the conditions required by the packaging process and send the containers to the packaging station one by one.
(a) Equal pitch screw feeding device.
The equal-pitch screw feeding device is shown in Figure 3-3.
Schematic diagram of equal pitch screw conveying device
1. Bottle trough; 2. Equal pitch screw; 3. Lateral track; 4. Horizontal conveyor belt
(b) Variable pitch screw feeding device.
The variable-pitch screw feeding device is shown in Figure 3-4. Figure 3-4(a) shows a device dedicated to feeding cylindrical packaging containers. The spiral groove on providing rod 1 gradually reduces the screw pitch along the feeding direction of the feeding oyster rod 1. The supplied packaging container moves on the stationary slide plate 2 against the lateral guide rails while rolling and decelerating. Figure 3-4(b) shows a device specially used for feeding prismatic packaging containers. The double annular groove gradually increases the pitch along the feeding direction of the feeding screw 1.
Schematic diagram of variable pitch screw bottle conveying device
1. Conveying screw; 2. Slide plate; 3 Side guide rail
(c) Special variable pitch screw feeding device.
The unique variable pitch screw feeding device is shown in Figure 3-5. The apparatus shown in Figures 3-5(a) and (b) can change the arrangement and spacing of the supply containers and play a role in splitting and merging so that the state of the container can be adapted to the following packaging requirements. Figure 3-5(c) shows a pair of screws arranged side by side with the same rotation direction. Their combined effect enables the packaging container to change the distance and the movement state during the feeding process. Enclosure 3-5(d) shows a feeding device composed of a horizontal variable pitch screw and 3 fixed crimping guide plates, making the supplied packaging container inverted and turned over.
Special variable pitch screw bottle conveying device
(a) Diversion (b) Turn (c) Confluence (d) Turn over
2) Conveyor belt
The commonly used container conveying equipment is a loose-leaf chain conveyor belt, as shown in Figure 3-6. The loose-leaf chain conveyor belt is made up of metal plates connected in series through hinges. The size of the plates matches the diameter of the container. Several conveyor belts can be arranged side by side when the transmission rate is high to form a wide conveyor belt. Sometimes two chainplates with a wide container diameter are used to make a conveyor belt. Curved conveyor belts with larger turning radius use special-shaped chainplates.
Loose-leaf chain conveyor belt
1. Adjustable bracket 2. Sliding baffle 3. Drive chain 4. Conveyor belt fixed lubrication nozzle 5. Speed control hand wheel 6. Ball bearing 7. Drive wheel 8. Leveling feet
To make the conveyor belt run smoothly, a plastic slide rail is set under it. The conveyor belt is driven and turned back by gears and is tensioned by its own weight. The two sides of the chainplate are placed on the plastic slide rail, and the slide rail plays the role of supporting the chain belt and preventing it from falling. During the conveying process of the container, it is required not to damage the label and not to be affected by broken glass slag.
Loose-leaf chain conveyor belts can generally be sprayed and washed with high-pressure nozzles in sections. Nevertheless, it is necessary to use a particular lubrication system and lubricant for lubrication. It should be noted that these lubricants will eventually enter the wastewater, but they are usually degradable.
The application and characteristics of the loose-leaf chain conveyor belt can be summarized as follows: ① It can be installed in single or multiple rows and can be used for curved conveying; ② Its maximum installation tilt rate is up to 7%. The difference in conveyor speed can be used to realize containers from multiple paths. It becomes a single channel and can avoid sudden changes in container speed. It is widely used as storage and buffer between single equipment to prevent bottle flow from blocking. The loose-leaf chain conveyor belt has become the most crucial conveying tool in the filling workshop based on the above characteristics. To realize the vertical transportation of the container (such as sending the container to the upper floor), a conveyor belt with a clamping hook can be used. The clamping hook with a rubber cushion is installed on the folding conveyor belt and moves together. Occasionally, the clamping conveyor belt on both sides is also used.
The function of the star wheel is to send the packaging container sent by the screw feeding device to the primary conveying mechanism of the filling machine according to the requirements of the packaging process; or to transfer the filled packaging container to the capping machine of the capping machine On the workstation, its structure is shown in Figure 3-7. In the figure, the radius of gyration Rc and the height of the star wheel h are mainly determined by the diameter and size of the packaging container.
Star wheel structure
1. Star wheel; 2. Wheel dial; 3. Shaft
2.Bottle holder lifting mechanism
The function of the lifting mechanism is to raise the delivered bottle to a prescribed height to complete the filling and then lower the filled bottle to the prescribed position. Currently commonly used lifting mechanisms are
Three structural forms.
Figure 3-8 shows the structure of the mechanical bottle holding mechanism. The bottle holding mechanism’s upper sliding cylinder 3 and lower cylinder 6 are combined with a pull rod 5 and a compression spring 2 to form an elastic sleeve. A rolling bearing 7 is installed on the supporting pin of the lower cylinder 6. The bottle holder 1 and the upper and lower cylinders 3 and 6 are raised and lowered along with the cam guide 8. Since the elastic sleeve composed of the upper and lower cylinders 3 and 6 is raised by the force of the compression spring, it has a buffering effect, which can not only ensure the sealing of the bottle mouth during filling but also has an excellent ability to adapt to bottle height errors. In fact, it is equivalent to a cylindrical cam-translating follower mechanism, except that the cylindrical cam is fixed. The translating follower can rotate around the central axis of the cylindrical wheel, and its relative motion relationship remains unchanged.
Mechanical bottle holding mechanism structure
1. Bottle holder 2. Compression spring 3. Upper sliding cylinder 4. Slide cylinder seat 5. Pull rod 6. Lower cylinder 7. Rolling bearing 8. Cam guide
The mechanical bottle holding mechanism has the characteristics of simple structure and convenient manufacture.
The bottle supporting mechanism relies on the spring force to lift the table with a fixed buffer effect. Still, there is a more significant spring force in the bottle drop and no bottle section, which will increase the cam wear and quickly bend the roller pin. The spring is easy to be effective in continuous work. Its pressing force is also limited to a certain extent.
Figure 3-9 shows the working principle of the pneumatic bottle holding mechanism. The lifting of bottle holder 1 is powered by compressed air with a pressure of (2.5 ~ 4) x105Pa.
Working principle of pneumatic bottle holding mechanism
1. Support platform 2. Cylinder 3. Piston 4. Exhaust valve 5. Intake valve 6.7. Air pipe
Pneumatic bottle holding mechanism structure
1. Bottle holder 2. Cylinder 3. Piston 4. Cock 5. Head seat 6.7 Air pipe 8. Air inlet 9. Exhaust hole
When raising the bottle, the intake door 5 is closed, the exhaust door 4 is opened, and the compressed air enters cylinder 2 from the air pipe 7, which pushes the live floc 3 together with the bottle holder 1 to rise. The atmosphere in the upper part of piston 3 is discharged through the exhaust valve 4. When the bottle is lowered, the exhaust valve 4 is closed. The intake valve 5 is opened under the control of the bumper next to the turntable. The compressed air enters cylinder 2 through air pipes 6 and 7 at the same time. Since the air pressures of the upper and lower pistons 3 are equal, the bottle holder 1 and the bottles are lowered under the action of their own weight. In practice, they can also be replaced by a cock. The cock is configured to replace intake valve 5. The other hole connects cylinder 2 to the atmosphere to replace the exhaust valve 4. Figure 3-10 shows the pneumatic -Type bottle holding mechanism structure.
The advantage of the bottle lifting mechanism is that the bottle is lifted quickly, and the compressibility of the gas is used to realize buffering and avoid the impact loss of lifting the filling bottle. The disadvantage is that the operation is not stable.
3) Mechanical and pneumatic combined type
Figure 3-11 shows the structure of the mechanical and pneumatic combined bottle holding mechanism. Sleeve 2, equipped with bottle holder 1, can slide along the hollow plunger 5, and the square block 8 acts as a guide to preventing sleeve 2 from deflection when raised and lowered. In the case of a long bottle, the compressed air enters from the lower part of the hollow plunger 5 through the central hole on screw 3.
The inside of sleeve 2 is used to push the bottle holder to move, and its speed is controlled by the cam guide 6 and the ball bearing 7; the compressed air inside the hollow plunger 5 is still discharged into the ring pipe connected to the gas circuit of each bottle holder cylinder. Then enter the other bottle holders that are waiting to rise.
Mechanical and pneumatic combined bottle holding mechanism structure
1. Bottle holder 2. Sleeve 3. Screw 4. Seal 5. Hollow plunger 6. Cam guide 7. Ball bearing 8. Square spacer 9. Ring tube 10. Clamping block
The combined supporting bottle lifting mechanism uses a pneumatic supporting bottle. The compressed air can be circulated in the loop tube to reduce power consumption. Therefore, it has a self-buffering function, stable lifting and saving time. At the same time, it combines the control of the cam guide rail to make the lifting and lowering movement of the bottle fast, accurate and guaranteed quality. This mechanism is widely used, especially for the equal pressure filling machine, because it is equipped with an air compression device, which is more practical.
The above three types of bottle holding machinery have their own advantages and disadvantages. The mechanical bottle supporting mechanism relies on the spring force to lift the table and does not need to be sealed. Still, the elastic charge is easy to fail in continuous work. The pressing force is also limited to a certain extent. It is mainly used for filling machines that do not contain gas and liquid materials. The pneumatic bottle holding mechanism uses compressed air as the power source and has good vibration absorption and buffering capacity. It is not easy to crush the bottle when it fails, but the movement speed of the piston is greatly affected by the change of air pressure. If the pressure drops too much, it will not only slow down the rising rate of the bottle, but also it will be difficult to maintain close contact between the mouth of the bottle and the filling head; if the pressure rises too much, the rising speed of the bottle will speed up, making it difficult to align with the feeding tube. Make the bottle subject to a strong impact. The mechanical and pneumatic combined bottle holding mechanism is stable and reliable in rotation. The compressed air is circulated in the ring pipe. It only needs to supplement the leakage. It is widely used. However, the cam guide will also increase additional lubrication, wear and running resistance.
Due to the existing air pressure system, it is advisable to adopt a pneumatic or a combined mechanical and pneumatic bottle holding mechanism for the equal pressure filling machine.
3. Feeding device for filling liquid
The feeding device of the filling liquid is a device that sends the fluid from the liquid storage tank to the liquid storage tank via the pump and the liquid infusion pipeline. It includes liquid storage tanks, pumps, pipes, valves, liquid storage tanks, height adjustment devices, liquid level controllers, etc. The structure of the liquid supply device of the filling machine for different filling methods is different. For details, see the liquid supply device of the filling machine for each filling method.
4. liquid level control device
Liquid packaging machines require a stable liquid level, generally controlled by a liquid level float valve or a liquid level electrode. Standard level control devices include float level controllers, electrical contact level controllers, conductivity type level controllers, and PLC control methods.
1) Float level controller
The float level controller is suitable for controlling the liquid level in the open or pressure container in the industrial production process. The float floats on the liquid surface, and its position changes with the liquid level fluctuation. Filling machines that do not require high filling accuracy and speed often use this controller. The high limit and low limit of the liquid level are divided into a high liquid level controller and a low liquid level controller.
(a) High liquid level control float.
(a) High liquid level control float. The high liquid level control float controls the highest liquid level in the liquid storage tank, and its structure is shown in Figures 3-12. When the liquid level in the liquid storage tank 4 exceeds the specified height, float 1 rise, the float rod 3 and the sliding sleeve 6 move the sealing ring 8 to the right, and the intake 7 is opened, so the sterile compressed air flows from the balance air pipe and passes through the inflation valve, Into the storage tank 4
Subsequently, the liquid material is pressed back to the reservoir. After the liquid level drops to a specified position, the low liquid level causes float 1 to lose buoyancy. Due to the weight of float 1 and the heavy hammer 2, the float rod 3 and the sliding sleeve 6 move the seal 8 to the left, blocking the air inlet 7 and stopping air intake. When the liquid level is high, the liquid level control float 1 rises and presses the air inlet 7 so that the gas cannot be released from the air release valve.
(b) Low liquid level control float.
The low liquid level control float controls the lowest liquid level in the liquid storage tank, and its structure is shown in Figures 3-13. When the liquid level in the liquid storage tank drops to a specified height, float 1 drop, and at the same time, float 1. The float rod 3 rely on its own weight to make the seal 4 leave the exhaust nozzle 7, and the gas in the upper part of the liquid storage tank passes from the exhaust nozzle. 7 is discharged, which reduces the gas pressure in the liquid storage tank, so the liquid material enters the liquid storage tank from the liquid storage. When the liquid level rises to the specified position, float 1 causes gasket 4 to block the exhaust nozzle 7. The needle valve 6 is used to adjust the exhaust speed.
Schematic diagram of high level control float
1. Floating ball 2. Heavy hammer 3. Floating ball stick 4. Reservoir
5. Float cover 6. Sliding sleeve 7. Air inlet 8. Sealing ring
Schematic diagram of low level control float
1. Floating ball 2. Heavy hammer 3. Floating ball stick 4. Gasket
5. Float cover 6. Needle valve 7. Exhaust nozzle
2) Conductivity liquid level controller
The conductivity type liquid level controller is a new type of liquid level control instrument. Because of its adjustable sensitivity, it has a solid anti-scaling ability for liquids with low conductivity. It is suitable for automatic liquid supply and discharge control in the light industry, chemical industry, water treatment and other industries, and various conductive liquids’ upper and lower limits. The controller connects the current of the control circuit by measuring the contact between the electrode and the conductive liquid. Then the control circuit converts the current signal into the contact switch output of the relay, thereby realizing the sensing of the liquid level. The control function is divided into single/dual channels. The single-channel can realize the height alarm or control of the liquid level of 1 point; the dual-channel can realize the height alarm of the upper and lower limit of the liquid level of 2 points or control the height alarm of the liquid level of 2 liquid cylinders. It is typically used for liquid level control in tap water, beverages, milk, and beer filling. Figure 3-14 shows that it is the upper limit point of the working liquid level, the lower limit point of the operating liquid level, and the lowest point of the liquid level in the cylinder. When automatic liquid level control, 3 electrodes with different lengths should be used. The sum can be selected appropriately to control the liquid level between the length difference of the aggregate.
Principle of Conductive Liquid Level Control
3) Tuning fork type liquid level limit switch
Tuning fork liquid level limit switch is a new liquid level control switch, also known as “electronic float”. Any float limit switch and the float limit switch cannot be used due to structure, turbulence, agitation, bubbles, vibration, etc. “Electronic floats” can be used for position switches.
Since the liquid level control switch has no moving parts, it does not need protection and adjustment. It is an upgraded product of the float level controller. Figure 3-15 shows that the tuning fork is excited by the crystal to generate vibration. When the tuning fork is immersed in liquid, the vibration frequency changes. This frequency change is monitored by the electronic circuit and outputs a switch value. The position of the two tuning forks can be adjusted according to requirements. Adjust the fluctuation range of the liquid level up and down.
Tuning fork liquid level limit switch
4) PLC level control
PLC has gradually been widely used in fully automatic filling machines and has become increasingly mature in recent years. It has convenient, broad applicability, high reliability, strong anti-interference ability, and simple programming. However, due to PLC, Large-scale integrated electrical appliances are more expensive than mechanical switches, relays and contactors. Figure 3-16 shows the schematic diagram of PLC level control.
Before starting, if the liquid level in the liquid storage tank does not reach the lowest level, press the start button to turn on the liquid inlet pump; when the liquid level comes to the upper limit position, the PLC controls the liquid inlet pump to stop. The controller will maintain the liquid storage tank. The liquid level is within a range (that is, the upper and lower limits are within the divide between the switches). As the filling progresses, the liquid level gradually decreases until the lower limit is controlled to open the liquid inlet pump. When the liquid level reaches the upper limit, the liquid inlet pump is controlled to stop.
In addition, there are a variety of liquid level controllers such as radiofrequency capacitive liquid level controllers, ultrasonic liquid level controllers, and electrical contact liquid level controllers, or they can be selected and used according to the requirements of the specific design of the filling machine.
PLC level control
5. Filling valve
The mechanism that fills the liquid in the liquid storage tank into the bottle is called the filling valve, which mainly includes
1) According to the number of valves
The valve body structure of the filling valve has a single valve type, double valve type and multiple valve type.
(a) Single valve type filling valve. A filling valve with only one gas or liquid valve is called a single valve type filling valve. For example, the air passage of the standard pressure filling valve is always open, so only one liquid valve is needed; the differential pressure type harmful pressure filling method eliminates a liquid valve and only a gas valve.
(b) Double valve type filling valve. A filling valve with both a liquid valve and a gas valve is called a double-valve filling valve. For example, there are 1 gas valve and 1 liquid valve in the gravity type negative pressure filling device; the mechanical pressure filling valve has 2 liquid valves in the filling machine.
(c) Multi-valve type filling valve. The multi-valve filling valve has various valves such as liquid valve, inflation valve, return air valve, pressure release valve, and cleaning valve.
2) According to the movement form of valve opening and closing
Filling valves include single-movement valves, rotary valves, multi-movement valves, and pneumatic membrane valves.
User Manual of Bottled Water Filling Machine
II. Machine Composition & Structure Instruction…………………
III. Technical Properties…………………………….……………
IV. Size & Weight ……………………………………..…………
V. Installation & Debugging…………….………………………
VI. Usage &Operation……………………………………………
VII. Common Fault Analysis and Clearance …………………
1. Characteristic of the product:
14/12/5 Cap produced by our factory is a washing, filling, cap-sealing machine. Based on our years of production experience, this machine is a new generation developed based on reaping study of domestic and foreign similar technology. The machine is an automatic multiple-function washing, filling and capping unit, using electric machinery for transmission. This product has the advantage of high automation, compact structure, Fine appearance，easy operation, safety, reliability, and continually adjustable production capacity. It is the perfect choice for washing, filling, cap-sealing machines.
2. Application scope
This bottling machine is suitable for filling and sealing round or other shapes of PT, PET bottles for mineral water, pure water, fruit juice, and so on. The machine uses imported electrical equipment, PLC computer control and frequency conversion control for the main electromotor.
Bottle type: Bottle capacity:250～1500ml
Bottle diameters ranges:￠50～￠90mm
Bottle height ranges:150～320mm
Bottle mouth inside micrometer:￠20～￠40mm
This bottle filling machine is made according to the corresponding safety standard. The structure guarantees safe operation based on proper maintenance. During the maintenance period, the machine can only run by hand or by inching switch.
When a safety device needs to be stopped during maintenance and repair, the machine can only be operated by a trained worker or a qualified person. Before turning on the electricity, make sure there is any obstruction on the path of bottles, rinsing tools and other places.
II Machine Composition & Structure Instruction
—- Bottle rinsing system —–Main transmission system
—- Bottle filling system —– Electric system
—- Bottle sealing system —–Conveying system
—- Pneumatic system —–Body frame system
2. Structure Instruction
The bottle rinsing section is composed of principal axis, fixing skeleton, liquid distributor, bottle gripper. Bottles feeding and conveying is completed by the synchronized motion of the big gearbox and other parts geared by the main transmission section.
2.1 Bottle gripper
Along with reverse rod move with rail, gripper body moves around axletree with the angle of 180 degrees. Roller wheel open against slight bumped by gripper which turns along with turnplate and tangent with bottle feeding locking plate, then the bottle is gripped.
In the photo, the reverse rod is wearing a part made from white POM.
2.2 Distributor system
The media distributor is used to lead the media from pipe to machine and switch valve and sprayer. All parts are made of food-grade stainless steel and unique material.
2.3 Filling system.
The filling system is composed of a liquid tank, axletree, lift unit and valves.
2.4 Tow bottle lift system
The part is contacted by roller and concave wheel curve; when the turntable turns around, the lifting shaft will go up along the cam, jack up the bottle, get the filling valve and complete filling operation, and then tow the bottle down.
The support and locating sleeve is a changeable part, by exchanging these two parts and related parts can suit different production requirements of varying bottle sizes.
The small roller and roller shaft is wearing part, which needs to be replaced at regular intervals.
2.5 Filling valve
The filling valve decides the filling speed and filling quality; all the material is made of high-quality stainless steel and nonpoisonous and tasteless rubber; all the O ring and spring are wearing parts, which need to be replaced at regular intervals.
2.6 Sealing system
2.6.1 The machine has a good sealing quality, compact structure, low noise, convenient maintenance; the bottle filling machine is made of the central principal axis, cap screwing head, cap sorter.
2.6.2 Cap screwing head and sliding bush
Working principle: screw capper and sliding sleeve couple together, when it turns around with the main bearing, gears of Cap screwing axle will engage with ring gear by intermediate load, and rotate by itself, to screw the caps tightly. If exceed, the rated torque, to protect caps or bottle from damage, screwing sleeve will keep still and only sliding bush and shell turn.
Adjusting of torque: lose the trip bolt-on adjust nut, turn clockwise, then torque will be smaller; after having the proper torque, don’t forget to tighten the trip bolt.
While using different bottle caps for sealing, the cap screwing ring will have to be changed.
Troubleshooting of cap screwing head
a. Caps falling while caps feeding in
Check if O ring (36*3.65) is too loose to lock the caps with three steel balls, and O ring should be replaced;
b. if caps are screwed into the right place, check the if screwing sleeve can turn; if not, take it apart to see if the magnet cylinders inside have uncoupled with inner & outer coupling rings, and they are snapped.
If it uncouples, replace the cylinder on the coupling rings, it will be better to stick them on the rings with glue.
When the turnplate of Hopper turns, caps on the right side will feed into the Cap falling tube; those not on the right sides will keep stirred in Hopper.
Start cap sorter’s motor; if a few caps fall down, the inter-space of turnplates will adjust to being bigger; if Cap falling down not in the right side, the inter-space should be smaller.
III. Technical Properties
3.1 Capacity：4000BPH （500ml）
3.2 Main parameter
Washing head: 14heads;
Filling head: 12heads;
Capping head: 5heads
Total main machine power: 3.67KW
Main motor: 2.2KW filling pump: 0.55KW
Cap arranging unit: 0.18KW conveyor motor: 0.37KW
Washing pump: 0.37KW
3.2.3 Water consumption:
Rinsing water: 0.8t/h
Filling water: max 6.5t/h
3.2.4 Pipes specs
Rinsing water pipes: Dg15, 1/2” pipe thread.
Filling water pipes: ￠38 Health pipe
PVC pipes for water drain
IV. Size & Weight
4.1 equipment size:
Length x width x height: 2380 x1650 x 2480（unit：mm）
4.2 equipment weight:≈2200kg
V. Installation & Debugging
5.1 Requirement of installation
Ground levels, load-bearing per square centimetre, is more significant than 10kg, building roof height is not lower than 3.5 meters.
5.2 Notes of installation
5.2.1 It seems this machine is very heavy; it’s unnecessary to fix it on the ground by anchoring the bolt. It should be installed based that it can carry more loads. Levelling this machine by adjusting its feet; it should work as high as the whole production line (between H=1200~1250mm); inspect if all adjusting and fitting parts are fixed, and moving parts operate freely.
5.2.2 Connect the machine with the conveyor; adjust to correct position and operation height.
5.2.3 Connect with outer pipes.
(1) Main filling liquid feed in the pipe;
(2) Compressed air pipe;
(3) Feed-in pipe for rinsing;
(4) Water return pipe for rinsing.
VI. Usage & Operation
6.1 Preparation and inspection before operation.
Purpose and principle for cleaning:
The cleaning purpose of the food production line is to ensure finished products can meet the specified quality standard.
Speedy water will flow through all those parts recyclings, through which filling liquid will flow, and then achieve a good cleaning effect. To improve this effect of cleaning, it can be increased to be aseptic.
There are two ways for every cleaning process: mechanical cleaning and sterilizing cleaning with hot water or steam. CIP cleaning can be repeated using related detergents; while cleaning, the loss of thickness or temperature can be compensated by the increasing concentration or reheating. How to repeated use, the detergent will depend on different situations; normal, it can be repeated use 2~3 times.
6.1.2. Notes of maintenance.
(1) No water enters into gears, axletrees. All residual liquid on sealing elements, inner side of operation table, or surface of oil paint should be cleaned.
(2) During maintenance of components, ensure no damage to surfaces, including all sealing elements and nonmetal parts.
(3) Those positions where need to be filled with grease lubricant; make sure there is enough lubricant during maintenance.
(4) Maintenance of accessories should follow the supplier’s instructions.
6.2. Idle operation
(1) Please peruse this user manual before machine operation to basically understand the main structure of this machine, features & functions of different structures. And understand several automatic operation functions as mentioned
(2) Connect the Power, idle running slowly (note forward running and backward running), check if transmission part operates normally if all safety devices are reliable.
(3) While idle running slowly, fuel mentioned parts, check if worm-gear reducer‘s lubricant reaches oil standard scale position, 20# lubricating oil is used.
6.3. Production operation
(1) Connect Power, start air compressor, adjust air pressure to be 0.6MPa
(2) Reset the emergency stop switch of the central electric control cabinet.
(3) Press liquid feed in switch, start caps feeder and sorter, Cap not in the right side will return to Hopper through recovery tube. After all control switches start, check if every section typically works, reset, return to the main control panel, and begin automatic operation.
(4) After the automatic operation start, the speed control switch slows down the machine’s running speed, bottles feed in, and trial running starts. Check to fill and sealing effect, take steps for any problem; if everything works in average, then production goes on, and begin from low production capacity; after skilled in operation, and everything is well, then increase production speed to rated capacity.
VII. Common Fault Analysis and Clearance
bottle gripper loose
not enough spring force
rinsing position not right
sealing position between distributor and fixed plate change
loose screws on distributor’s moving plate, and adjust to a right position
rinsing liquid leak from distributor
distributor’s fixed plate and moving plate not sealing not well.
Tightening adjusting screw on lower end of distributor
few water spray
water pressure low, or pipes are jam
check water pressure, and if pipes are bended
big difference between liquid levels inside bottles.
vent-pipes length are not equal, sealing plate damage, bottle is not sealed
Increase vacuum degree of liquid tank
Valve’s inner seal ring damage, or liquid level too high
Replace seal ring, check if control flow ball damage.
Capping not tight enough, leakage
Distorting force to small
increase distorting force
screwing moment too big,
decrease screwing moment
8.1 Daily Maintenance after production is complete.
(1) Drain residual liquids inside media pipes. Empty liquid tank and pipes, clean up remaining caps in Hopper.
(2) Clean up bottles and sundries on the working table and conveyor chain.
(3) Check star wheel, screw rod, bottle guide plate. If there is any problem, please solve it or replace it.
(4) Check if the rinsing part’s media converter and media converter valve are standard.
(5) Check if the rinsing part’s gripper is damaged.
(6) Check if the filling valve is damaged.
(7) Check if Hopper’s slideway is damaged.
(8) Cleaning machine inside and outside after production finished, and it will be better to fuel those lubricating points after cleaning.
8.2 Weekly maintenance.
(1) Check if height adjustment is flexible.
(2) Check the wear of the rinsing gripper’s plastic part.
(3) Check elasticity of filling valve’s spring if sealing plate damage.
(4) Check filling pipes and clean them up.
(5) Check rinsing media distributor, filling distributor.
(6) Check and fuel lubricating points inside the gearbox if needed.
(7) Check conveyor gear and maintenance.
(8) Check and clean up Hopper.
8.3 Monthly maintenance.
(1) Check wear of tow bottle guide plate and bottleneck filling distance plate
(2) Check wear of rinsing clamp cam, filling lifting roller wheel, and cap sealing sliding bush.
(3) Check and maintenance moving parts, adjust, repair or replace them.
8.4 Maintenance every 6 months.
Apart from the maintenance mentioned above, minor repairing, whole machine adjusting, cleaning, fueling or replacing parts should be done every 6 months or every busy production season.
Common quality problems of bottled water production
1. Causes and solutions of residual chlorine
|The amount of chlorine added in the original pool is too large, and the residual amount has exceeded the adsorption capacity of activated carbon.||Control the amount of chlorine added in the original pool to 6-8ppm. The amount of NaClO added can be determined according to the effective chlorine concentration of the NaClO stock solution.|
|Insufficient reducing agent or low effective concentration causes excessive chlorine to enter the activated carbon, and the activated carbon has reached a saturated state.||1. Monitor the reducing ability of each batch of reducing agents to make the reducing ability meet the process requirements|
2. Make sure that the concentration of the added amount in the water is 3 times that of the residual chlorine of the mechanical filter. (Regularly check the stroke and frequency of the pump to ensure accurate measurement.)
|The adsorption capacity of activated carbon is saturated or invalid.||1. Rinse the activated carbon filter regularly|
2. Regularly regenerate activated carbon to restore its adsorption capacity for residual chlorine
3. Periodically verify the ability of activated carbon filters
|Quality control does not monitor the residual chlorine indicators in place.||1. Strictly follow the regulations to track the residual chlorine indicators in each part of the water treatment room and take corrective measures immediately if there is an abnormality|
2.Causes of water leakage and solutions
|Perforation at the thread or neck of the bottleneck, and mechanical scratches||1. Improve the performance of the bottle blowing machine manipulator 2. Strengthen the equipment capabilities of the unscrambler, bottle conveyor, filling machine (stopping knife), and the production line’s conveyor path to avoid damage caused by the equipment 3. Strengthen the control of light inspection|
|Folded lid, crooked lid, invisible high lid cause water leakage||1. Strengthen the inspection of raw and auxiliary materials and do an excellent job of bottle cap testing machine; 2. Ensure that the cap and bottle match are consistent. If inconsistent bottles or caps are used, follow up on the production situation in time. It is necessary to stack and invert the box. 3. Adjust in time Capping head 3. Strengthen the control of inspection links|
|The cap is not tightened||1. Ensure that its torque is 9~13 pounds·|
|Incomplete or small holes in the mouth or body of the bottle||1. Strengthen the quality inspection of raw material tube blanks 2. Strengthen the quality control of empty bottles in the blowing room 3. Strengthen the control of the inspection position of the production line|
3.Common problems and solutions for label sleeving and labels
|The label has ghosting, chromatic aberration, extra lines, and small folding diameter||1. Strengthen label warehousing inspection 2. The operator of the sleeve labelling machine strengthens random check during use and finds abnormalities, and immediately stop using it|
|Shrink and wrinkle||1. The steam pressure is too high or too low, and the steam valve’s flow rate in different positions is not adjusted correctly. 2. Strengthen the online inspection|
|Inaccurate sleeve position||1. Adjust the operation of the sleeve labelling machine；2. Strengthen online inspection|
|The uneven thickness of the bottle and the white bottom of the bottle reduce the pressure resistance of the bottle. In the subsequent process, it is straightforward to be squeezed and deformed.||1. Control the quality of blowing bottles 2. Strengthen the inspection of empty bottles|
|There are too many bottles in the bottle storage, squeezed and deformed, and the bottle unscrambler is stuck and twisted.||1. Control the number of storage bottles|
2. Adjust the unscrambler in time so that it will not damage the bottles. If the unscrambler gets stuck in the bottle, it should be adjusted in time
3. The quality inspector should select bottles with uneven thickness, whitishness and deformation in time
|Deformation of the filling machinery, such as thread hanging caused by the stop-rotating knife, etc.||1. The bottle deformation caused by the filling machine should be adjusted or replaced in time.|
2. Strengthen online quality inspection, and pick out products with deformed bottles and serious hanging silks
|Deformation caused by squeezing of blocked bottles on the production line||1. Right the inverted bottle in time|
2. The chain of blocked bottles should be unblocked in time and kept unblocked
|On the packing track, artificially used long rods to unscramble bottles to cause deformation||1. Improve the way of unscrambling bottles on the packing track|
2. Pay attention to the operation method of the unscrambler
|Production line quality inspection omissions||1. Strengthen quality inspection|
5.Common problems and solutions for coding machine
|The coding is blurred and unclear||1. The air pressure tube is unstable, the bottle cap is not blown dry, the ink is not enough, or the concentration is not enough. Let the operator adjust the pressure of the air pressure tube and replace the ink.|
2. Let the light inspectors select unqualified products
|Missing code||1. The recovery pipe is blocked, and the printing delay is too long or too short. Let the operator clean the nozzle of the printer in time to make it work typically. 2. Inkjet printer mechanical failure should be shut down to solve 3. Strengthen quality inspection|
|Inaccurate coding||1. The code skipping at zero every day is not followed up in time. 2. The mechanical failure of the printer is solved. 3. The quality inspection is strengthened.|
|Recode||1. The coding of recycled products should be wiped clean 2. Strengthen the quality inspection of wiping and coding|
|The plastic smell of PET bottle due to high temperature||1. Use cold bottles in the production process|
|Lid smell||1. Improve the purity of the colour mesh in the raw material|
|NaOH exceeding the standard (astringent taste, bitter taste)||1. Strengthen quality control and testing, strictly control the working state of the NaOH metering pump. 2. Ensure the COP and CIP flushing procedures, control the flushing water to an average value, and avoid chemical odours. 3. Pay attention to keep the reflux tank clean in the filling room|
|Microbial reproduction||For details, please refer to Article 10. 1. Strict sterilization, maintain mechanical filtration residual chlorine ≥ 0.3ppm, finished water O30.4—0.6ppm 2. Regular tracking of microbial control links and timely corrective measures for abnormalities (raw water, activated carbon filters, irrigation, Filling the first, etc.) 3. Prevent secondary pollution and cross-contamination (such as the use of recycled bottles must comply with the cleaning procedures or the pollution of bottles, caps, and tube blanks must be isolated and treated in time)|
|The excessive residual chlorine (bleaching powder flavour)||1. Strengthen the inspection of the water treatment room, such as the monitoring of residual chlorine after mechanical filtration, NaHSO3 addition, and the effectiveness of activated carbon adsorption (see Article 1 for details)|
|The oily smell from bottle contaminated with oil||For details, please refer to Article 13|
|The bitterness of lubricant intrusion||For more information, please refer to Article 14|
|Filter failure in the water treatment room||1. Strengthen the monitoring of the inlet and outlet pressure of the filter in the water treatment room. If it exceeds the standard, clean it; 2. Strictly follow the water treatment CIP cleaning procedure|
|Mechanical debris such as rupture of the sealing ring of various pipeline interfaces, wear of the filling head, and dirt accumulated on the filling head.||1. Check frequently and replace the sealing ring in time 2. Clean the filling head regularly|
|Severe pollution of the bottle cap||1. When bottles and caps enter the factory, it is required to strictly follow the sampling inspection|
2. Strengthen the hygiene of the cover room and strictly follow the COP cleaning and disinfection procedures
|The empty bottle is not rinsed thoroughly, or the rinse water does not meet the process water requirements.||1. Increase the pressure of the bottle-rinsing water so that the bottle-rinsing water can be flushed entirely to all parts of the bottle|
|The bottle silo, bottle unscrambler, and air duct (including fan filter cloth) in the bottle blowing room do not meet the hygiene requirements, causing the bottle to be contaminated.||1. Ensure that the flushing water meets the requirements of process water|
|Lamp leak detection||1. The environmental sanitation of the blowing room is strictly implemented by the requirements of the production operation instruction;|
2. Replace the fan filter cloth in time
|Inadequate mosquito control facilities and measures||1. Improve mosquito control facilities and clean them regularly|
|The use of recycled bottles does not meet the requirements.||1. The use of recycled bottles must comply with the cleaning procedures|
8.Insufficient net content
|The bottle itself is not enough.||1. Adjust the parameters of the bottle blowing machine and check that the filling capacity is qualified before blowing.|
|Insufficient filling volume caused by water splashing inside the bottle caused by mechanical vibration||1. Adjust the equipment to reduce the vibration and prevent the material liquid from splashing|
|The filling speed is too fast.||The filling speed should be controlled within a specific range|
|The filling head is blocked by debris, or the filling head is broken||Perform equipment COP and CIP regularly, and replace the filling head in time|
|Quality inspector omissions||Strengthen the work of light inspection and online quality inspection personnel, and implement a rotation system at the same time|
9. The ozone content of purified water is unqualified
|PH in water is slightly alkaline||1. Strengthen the monitoring of the PH value and the working status of the water treatment metering pump|
|The water in the secondary tank has been left for too long||1. The secondary water that has been left for more than 2 hours should be discharged as required; if the ozone concentration is unqualified during the re-production within 2 hours of production shutdown, it can be mixed with fresh higher-concentration ozone water|
|There is water in the pipes and equipment, and the downtime is too long||1. If the machine is shut down for too long, the secondary water accumulated in the equipment should be drained.|
|Whether the test result is accurate||1. Ensure the accuracy of quality control testing data|
|Ozone generator failure||1. Repair the ozone generator|
|Unstable voltage, water volume and air pressure||Adjust to the specified parameter range|
|Desiccant failure occurs||Check the desiccant regularly and replace it in time|
|The ozone generator parameter setting is unreasonable.||Adjust the parameters in time according to the detection value|
10.Microbiological problems and solutions for bottled drinking water
|Insufficient amount of NaClO added in the original pool (6–8ppm)||1. Detect the available chlorine content of NaClO in the factory and add NaClO strictly according to the process requirements|
2. Monitor the flow of the NaClO metering pump
|The activated carbon filter is used for too long, breeding bacteria||1. Strictly implement activated carbon washing and sterilization anyway, sampling for microbiological testing to confirm the effect of washing and sterilization|
|Ozone concentration is not up to standard (0.4-0.6ppm)||Adjust the PH value (the amount of NaOH added) and the relevant parameters of the ozone generator to ensure that the ozone concentration is 0.4-0.6ppm|
|The security filter is not cleaned and disinfected in time||Periodically soak in 0.005% peroxyacetic acid for 30 minutes. When the inlet and outlet pressure difference is ≥0.5Mpa, replace the filter.|
|The reverse osmosis membrane was not cleaned in time||Regularly clean the reverse osmosis membrane.|
|Sterilization of bottles and caps||1. The empty bottle should be used in time, and it should be cleaned and disinfected after being placed for too long; 2. The bottle cap should be guaranteed to be pollution-free and ozone sterilized for more than 2 hours|
|Cap tightness||1. Strictly check and accept packaging materials to ensure the consistency of bottles and caps; 2. Control the torque of bottle caps during the production process within the standard range 3. Check out abnormal products such as high caps and crooked caps in time|
|Environmental sanitation control||1. Clean and disinfect the bottle blowing room, water treatment room, and filling room as required to ensure regular spray disinfection of the ground, walls, space, and trenches; 2. The area with ozone and ultraviolet light disinfection should be disinfected regularly|
|The pipeline system is contaminated by microorganisms||1. Carry out proper CIP cleaning and soaking of the pipeline system as required. 2. Pay attention to the cleaning and disinfection of the return tank in the filling room.|
|Incomplete cleaning and disinfection of equipment COP||1. Regularly wipe and disinfect the bottle conveying system (tube embryo warehouse, bottle warehouse, air duct, fan filter cloth, etc.) as required 2. Regularly clean and disinfect the surface of the equipment in the water treatment room and the filling room|
|The hygiene of production operators does not meet the norms||1. Production workers must strictly follow personal hygiene regulations|
|The use of recycled bottles does not meet the requirements||1. The use of recycled bottles must comply with the cleaning procedures|
|Out of control of microbial control||Regularly track the microbial control links, and take corrective measures in time if there are abnormalities (such as raw water, activated carbon filters, filling heads, etc.)|
|Environmental factors in the microbiology room and operators may lack rigorous operation.||Microbiology room testing should ensure the reliability of environmental factors, and micro-inspectors must operate by microbiological operating procedures.|
11.Excessive heavy metals
|Abnormal raw water quality (excess iron and manganese)||1. The operation of the manganese sand tank of the raw water should be monitored, and the comprehensive index analysis and testing of the groundwater should be carried out regularly to guide the subsequent water treatment 2. It is forbidden to join any abnormal groundwater|
|Excessive addition of flocculant||Determine the concentration and flocculation effect of the flocculant, accurately determine the additional amount, and track the content of iron and heavy aluminium metals.|
|The filtering effect of the water treatment system is not good, such as the failure of the security filter.||Send the water samples before and after filtration regularly, confirm the filtration effect, take corrective and improvement measures, and clean the security filter periodically or when the pressure difference between the inlet and outlet is ≥0.5Mpa.|
12.Reasons and solutions for the high or low PH value of purified water
|Abnormal raw water quality||1. The pH of the raw water should be monitored, especially groundwater, to guide the subsequent water treatment;2. It is forbidden to join any abnormal groundwater|
|The addition amount of NaClO, NaHSO3, and NaOH is abnormal||1. Adjust the corresponding drug metering pump, and adjust the dosage according to the residual chlorine and pH of the effluent|
|The function of the reverse osmosis membrane is reduced or invalid, resulting in a higher PH value of the secondary RO water||1. Control the amount of scale inhibitor before reverse osmosis. The water temperature, residual chlorine, and PH value must be controlled. It cannot be operated under exceeding the standard, which will damage the reverse osmosis membrane. At the same time, the reverse osmosis membrane must be cleaned regularly.|
|When the downtime is extended and the reverse osmosis equipment is started again, the low and high-pressure flushing time is not enough. There is water in the RO membrane that has not been drained, which increases the PH value.||1. When the reverse osmosis equipment is turned on and off, the low-pressure flushing time should be sufficient; when the reverse osmosis is restarted after stopping for some time, the low-pressure flushing time should be extended to 1h. The high-pressure feed water should be flushed for 10-15min, and NaHSO3 is used. Before the RO membrane of the protective liquid is put into operation, it must be washed for more than 6 hours. 2. Find out the corresponding relationship between the PH value of the secondary water displayed on the reverse osmosis equipment meter and the actual measured value so that the water treatment operator can observe and judge the actual change of the PH value at any time, and make timely adjustments to stabilize the PH value.|
|Laboratory testing equipment error||The usage of the PH meter should be checked.|
13.Quality problems with oil in the water
|During the daily maintenance process of the bottle blowing machine, the lubricant is added excessively, and the phenomenon of dripping oil appears; during the production, the oil is spilled on or in the bottle due to the centripetal force of the rotation. At the same time, if it enters the bottle warehouse, it will cause other bottles to contaminate||1. Pay attention during maintenance and add the proper amount of lubricating oil.2. Strengthen supervision after maintenance|
|The floor of the bottle blowing room was seriously oily, the floor tube or bottle was contaminated, and the operator was thrown into the genuine basket in violation of regulations.||1. Strengthen training for operators; 2. Strengthen ground cleaning and sanitation|
|When the Tech-Long blow moulding machine is turned on, the oil stays serious, and the bottle is full of oil.||1. Production can only be carried out after passing the inspection before each production; 2. Strengthen the inspection of the first product|
|The lubricating oil on the bearings on both sides of the mould of the semi-automatic bottle blowing machine accumulates seriously, which is easy to touch when taking the bottle, which causes the bottle’s surface to be contaminated the inside of the bottle is contaminated in the subsequent operation.||1. Add proper lubricating oil;2. Online operators strengthen supervision;3. Strengthen training for online operators;4. Quality control personnel strengthen supervision and inspection|
|The billet has been contaminated with oil before use||Strengthen inspection before use|
|The filling machine is leaking oil. For example, the leakage of lubricating oil from the filling head and capping head causes contamination of the finished product.||Overhaul the equipment at any time|
|After the filling machine failed, the maintenance personnel did not completely remove the oil stains leaked due to repairs in time, resulting in pollution during reproduction.||Training for maintenance personnel should be thoroughly cleaned after maintenance. After the care of the machine, online quality inspection personnel and quality control personnel should strengthen supervision.|
|The quality awareness and sense of responsibility of the production staff are seriously insufficient.||Relevant training must be arranged immediately.|
|The air compressor has poor sealing and oil leakage, causing small oil particles in the compressed air to be contaminated during the blowing process of the bottle.||The engineering department overhauls equipment and strengthens online training.|
|It was caused by the illegal use of empty bottles to contain other items at the scene.||Strengthen site management|
|Pollution during transportation||Pay attention to protection during transportation|
14.Contamination of bottle lubricating fluid
|The high concentration of lubricating fluid can easily cause severe pollution of the bottle itself.||1. On-site quality control tests the lubricant concentration according to standards; 2. Waterline personnel turn on lubricants according to standards|
|The recycling bottle itself has a lubricating tuck on the chain and mixed together and rubbed against each other, resulting in cross-contamination.||1. Waterline personnel strengthen the cleaning and disinfection control of recycled bottles; 2. Quality control strengthens the control of recycled bottles|
|The production line drain pan leaks water directly drips into the recycling frame caused by pollution.||Engineering department repairs in time|
|When spraying the loosening agent of the conveyor chain between the bottle blowing, the operation is not very standardized, and the spray to the bottle mouth or the bitterness of the loosening agent in the bottle.||1. Production line personnel are prohibited from spraying loosening agents and other chemical agents; 2. Quality control strengthens on-site supervision|
|The concentration of lubricating fluid in the chain channel is too high. The bottle is not lifted up in time by the conveyor chain, which causes the bottle body to be seriously stuck with lubricating fluid.||1. On-site quality control tests the lubricant concentration according to standards; 2. Waterline personnel turn on lubricants according to standards|
|The staff at the packing machine directly spilled lubricant from the bottle onto the conveyor chain, causing the bottle to be seriously contaminated. Similarly, when the finished product was packed upside down, it infected the bottle mouth, causing the bottle mouth to have a bitter taste. The plastic box of the packing machine can be contaminated with recycled bottles.||1. It is forbidden for employees at the packing place to directly add lubricant; 2 The packing and palletizing of finished products is temporarily standing upright; 3. Quality control strengthens on-site supervision|
|Water accumulated on the machine in the filling room, causing the recyclable bottle to be contaminated with lubricant.||1. Clean up the filling machine in time; 2. Strengthen the control of recycled bottles|
15.Causes and solutions for flocculent precipitation of mint water
|Weighing utensils, containers||1. The weighing instruments and containers are cleaned, disinfected and soaked in strict accordance with the standard requirements|
|Ozone concentration||1. Maintain the ozone concentration of production water and products above 0.5ppm|
|Melting of AK sugar||1. The melting of AK sugar should be carried out in a clean environment and keep boiling for 30 minutes after boiling|
|Sterilization of bottles and caps||1. The empty bottle should be disinfected by ozone and used in time. It cannot be used after being placed for more than 12 hours; the recycled bottle cannot be used. 2. The bottle cap should be guaranteed to be pollution-free and ozone sterilized for more than 2 hours|
|Cap tightness||1. Strictly check and accept packaging materials to ensure the consistency of bottles and caps; 2. Control the torque of bottle caps during the production process within the standard range 3. Check out abnormal products such as high caps and crooked caps in time|
|Environmental sanitation control||1. Clean and disinfect the blowing room, blending room, weighing room, and filling room according to the mint water production operation instruction requirements to ensure that the ground, walls, spaces, and trenches are regularly sprayed and disinfected; 2. Ozone and UV lamps are provided. The disinfected area should be disinfected regularly|
|The pipeline system is contaminated by microorganisms||1. Carry out proper CIP cleaning and soaking of the piping system according to the requirements of the mint water production operation instruction (particular attention should be paid to the cleaning and disinfection and soaking after the shutdown or after the carbonic acid product is produced) 2. The reflux tank in the filling room should be cleaned, disinfect|
|Incomplete cleaning and disinfection of equipment COP||1. According to the requirements of the mint water production operation instructions, the bottle conveying system (tube embryo warehouse, bottle warehouse, air duct, fan filter cloth, etc.) should be wiped and disinfected regularly. 2. The surface of the equipment in the mixing room and the filling room should be regularly cleaned and disinfected.|
|Production operator hygiene||1. Production workers must strictly follow personal hygiene regulations|
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