Beverage & Juice Bottling

The beverage and bottling industries are significant contributors to the global economy. They provide a wide range of products to meet diverse tastes and preferences. These industries produce, bottle,distribute, and sell liquid beverages, such as carbonated drinks, juices, beers, wines, spirits, sparkling
water, and energy drinks.

The market offers two types of beverages: Alcoholic and Non-Alcoholic.

Alcoholic beverages include beer, wine, and liquor, while non-alcoholic beverages include milk, soda, juice, and water. These facilities also produce concentrates. These industries use traditional and modern techniques to meet consumer demands and environmental standards.

There are two main processes used in the beverage production

Formulation of Liquid

The formulation liquid is typically used as a base for blended beverages that require additional additives, such as juices, concentrates, or water. Other beverages may require mixing, infusion, or blending at a later stage.

The formulation of the liquid beverage process consists of the following stages

Raw materials for the liquid are transported to the plant using trucks, rails, or pipelines. These materials may either be treated immediately or stored for later use. Tanks are reserved for specific times, and bulk storage facilities are self-contained, clean, and sanitized.

All items undergo laboratory evaluation before being allowed into the facility. Dry materials are transported through the same channels and are often added to each batch during the final testing for clearance.

During the production of each beverage, a mixing or blending process is used to create the final product. This process occurs in various locations, including mix plants, batch plants, kitchens, and laboratories. Mixing involves combining raw or blended components in vats, cauldrons (large storage containers), mixers, blenders, and tanks.

Each vat is typically used for a single production run, and additional operations may occur during this step, depending on the specifications of the final product. These operations may include carbonation, fermentation, pasteurization, sterilization, heating, boiling, and chilling. Recently, UV has been introduced into these manufacturing stages.

Beverages are usually stored for a long time after being made. This storage can occur as part of the beverage formulation or in a temporary holding facility before packaging. It is essential to closely monitor these storage containers to ensure that the final product is safe and consistent for consumers. This helps prevent spoilage and contamination, which can affect the quality of the beverage.

Products used in the different stages of the Formulation of Liquid Beverage Process

Packaging of the Liquid Products

Liquid beverages are typically packaged in plastic or glass bottles, aluminium cans, or waxed containers like milk cartons. Customers can request various forms and sizes to meet their demands. These containers are either prepared in-house or by an external vendor. The containers can be either blank for labeling after filling or labeled and ready for filling.

It is essential to maintain sanitary conditions as these containers are nearing the end of their use with liquid products. The containers are stored in the warehouse until transported onto the line.

Beverage containers are delivered to the plant via truck or rail and are stacked and palletized upon arrival. The first step in packaging is to remove the shrink wrap from each pallet or bulk bundle to prepare for individual handling and treatment. This helps ensure that the items can be safely managed and processed. A depalletizer, which can dispense each container mechanically or pneumatically, is used to accomplish this. The containers are then conveyed to the washing facility using air conveyor systems, inline bottles, and can lines.

Each container experiences a series of steps during the washing process to guarantee a safe and clean environment before coming into contact with the liquid product. They are disinfected, washed, rinsed, and sanitized. This is a crucial step in maintaining a hygienic environment. Once the containers are sterilized, they are sorted and prepared for final filling.

The product is moved from the storage facility and poured into the container during the filler process. Even though this process is done at high speed, the liquid flow is typically under light pressure to ensure that each container is filled accurately.

The most common type of filler is the carousel filler, which contains multiple heads. Each head has a cylinder, plunger, and spring. The spring adjusts the plunger to distribute the correct amount of liquid as the carousel rotates. This allows for the creation of various product types and sizes at a single facility.

After filling the containers with liquid, they are sealed with caps, crowns, or seals to prevent spills. The capping solutions are adjusted to fit the containers and ensure the closure is perfectly secured, even if there is any vibration. Finally, the containers are sealed for the last time to ensure the product remains safe and secure.

Filled containers are transported from the filler room using conveyors. Since conveyors can quickly fill up, most facilities include overflow or accumulation conveyors to stack products before distributing them. The products are then transported to labellers who package them. The final step is to ensure product safety before the beverage is distributed. This process may involve chilling, warming, pasteurization, UV sterilization, or adding ozone to the product for final formulation.

Labels are usually applied to containers after the sealing process. Each container should be labeled individually, whether a can, bottle, plastic or wax carton. Rotating the container facilitates the labeling process.

All sides, including the top and bottom, should be labeled. Labeling involves either printing directly on the container or attaching a paper or plastic label with an adhesive.

To ensure proper identification of each container, use sponges, brushes, and suction cups to align and insert.

Packaging individual containers involves placing them in a vessel that can hold up to 48 units. This vessel could be made of a simple plastic connector connecting separate units. Fiber or cardboard boxes/packages store six or more units. The entire process is timed using electronic,
mechanical or a combination of both methods.

Clutch/brakes are typically used to ensure appropriate container loading. The containers are then slid into cases using either a linear rail and block unit or a guiding rail.

The role of a palletizer is to manage incoming cases and arrange them on pallets in an organized manner. It ensures that the cases are tightly packed and appropriately indexed, allowing the next level of cases to be added. As more cases accumulate on top, the pallet is deemed full. The filled pallets are then stored in various units, which can be shrink-wrapped or banded together.

Handling container and liquid products with care is essential to guarantee consumer safety and avoid any issues upon delivery.

Products used in different stages of Packaging of Liquid Beverage

Mounted Bearings
Unmounted Bearings
Belts
Brakes
Cam Followers
Flat Top Chain
Roller Chain

Clutches
Conveyor Component
Conveyor Belting
Couplings
Lubricants
Motors
Speed Reducers
Sprockets
Sheaves

Exim Engineering specializes in providing comprehensive services to the beverage industry. We understand the challenges and opportunities of this industry and are committed to improving every aspect of bottling lines. Our solutions are designed to improve performance, minimize downtime, and
increase revenue. We offer a range of products that meet the industry’s strict standards for hygiene, precision, and automation, including conveying systems, bearings, bottle capping solutions, and food grade lubricants.

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