Product Overview
The ZLGF series rinsing-filling-capping monoblock is a rotary filling system independently developed for the beverage industry, combining three core processes: bottle rinsing, liquid filling and cap sealing. The integrated design eliminates intermediate conveying links, greatly reduces the risk of secondary pollution, and significantly saves floor space compared with split-type equipment.
All parts in contact with products are made of food-grade 304 stainless steel with mirror-polished surface, free of sanitary dead corners and fully compliant with food safety standards. The machine is equipped with an industrial PLC control system and touch screen HMI, supporting parameter setting, real-time status monitoring, production counting and fault alarm functions. The rotary continuous working structure ensures smooth high-speed operation and supports 24/7 uninterrupted production.
This series covers 9 standard models with capacity from 3,000 to 35,000 bottles per hour, compatible with PET bottles of 200–2000ml in volume. Format changeover can be completed simply by adjusting star wheels and guide rails, with short downtime and high flexibility. It can be matched with bottle unscramblers, sterilizers, labeling machines and shrink wrappers to form a complete automatic beverage production line, widely applicable to drinking water, fruit juice, tea beverage and plant protein drink production.
Equipment Principle
The machine adopts rotary continuous working principle, driven by gear transmission and cam indexing mechanism to realize precise synchronous operation of all stations. The whole process is fully automated as follows:
- Rinsing Station Empty bottles are fed into the rinsing turret via the infeed star wheel. Bottle clamping grippers hold the bottle neck and rotate it 180° with the mouth downward. High-pressure clean water sprays the inner wall thoroughly to remove dust and impurities. After draining, bottles are rotated back and transferred to the filling station.
- Filling Station Rinsed bottles enter the filling turret through the transfer star wheel. Filling valves align accurately with bottle mouths, and adopt atmospheric gravity filling principle suitable for low-viscosity non-carbonated liquids. The filling volume is controlled by precise liquid level principle to ensure consistent filling accuracy. After filling, bottles are smoothly transferred to the capping station.
- Capping Station Filled bottles are conveyed to the capping turret. The cap sorter automatically sorts and feeds caps to the capping heads. Each capping head picks up a cap and applies constant torque to tighten it onto the bottle mouth, ensuring leak-proof and uniform sealing. Finished products are finally discharged to the downstream conveyor via the outfeed star wheel.
The whole machine runs in a fully enclosed protective cover to isolate external pollution, with all stations smoothly connected to realize high-efficiency and hygienic continuous filling production.
Equipment Features
- 3-in-1 integrated design: Rinsing, filling and capping integrated in one unit, compact layout with small footprint, reducing secondary pollution risk
- Food-grade hygienic construction: All product-contact parts are 304 stainless steel, mirror polished, no sanitary dead corners, compliant with food industry standards
- High filling accuracy: Gravity filling valve with precise liquid level control, filling accuracy ≤±1%, no dripping, low material loss
- PLC intelligent control: Industrial PLC + color touch screen, with production counting, speed adjustment, fault self-diagnosis and alarm functions
- Wide bottle compatibility: Adaptable to 200–2000ml PET round bottles, square bottles and special-shaped bottles, quick and easy format changeover
- Stable continuous operation: Rotary transmission structure with smooth running and low noise, wear-resistant core components, suitable for long-term production
- Multiple safety protections: No-bottle no-fill, no-cap alarm, overload protection, emergency stop device, ensuring equipment and personnel safety
- Variable frequency speed regulation: VFD control allows flexible adjustment of production speed to match different production demands
- Easy maintenance: Quick-disassembly structure for wearing parts, convenient daily cleaning and maintenance, low operating cost
- Customizable configuration: Optional CIP cleaning system, online detection, remote monitoring and other functions according to customer requirements
Technical Parameters
表格
General Specifications
- Applicable bottle volume: 200–2000ml
- Applicable bottle diameter: φ50–φ100mm
- Applicable bottle height: 150–320mm
- Power supply: 380V 50Hz, 3-phase 4-wire
- Control mode: PLC programmable control + touch screen
- Product-contact material: 304 food-grade stainless steel
Data is subject to continuous R&D improvement, for reference only. Specifications are subject to change without prior notice.
Application Fields
Beverage Industry
- Bottled purified water, mineral water and drinking water production
- Fruit juice, concentrated juice and blended juice beverage filling
- Black tea, green tea, herbal tea and other tea beverage production
- Plant protein drinks, soybean milk and almond milk filling
- Functional drinks, vitamin water and flavored water production
Other Liquid Food
- Bottled vinegar, soy sauce and light condiment filling
- Liquid dairy products and lactic acid bacteria drinks
- Bottled herbal extracts and plant beverages
