Complete Bottling Line

Complete Bottling Line

A complete bottling line is an integrated system that enables beverage packaging from empty containers (bottles, cans, cartons) through to finished products stored on pallets. The line comprises different machines varying in function according to the container type, bottled product, and required production speed.

Production capacity is measured in bottles per hour (BPH), determining the level of automation required. At minimum, a bottling line can consist of a single filling monoblock (filler and capper), while high-volume operations require fully automated systems handling hundreds of thousands of bottles per hour.

Bottling Line Configurations

Manual and Semi-Automatic Lines

For small to medium production volumes (few hundred to few thousand BPH), bottling lines may operate with minimal automation:

• Bottle loading — operator manually places bottles on accumulation table
• Filling and capping — automatic monoblock processes bottles
• Labeling and packing — operator handles downstream operations manually

This configuration suits small wineries, oil mills, and specialty producers bottling wine, vinegar, oil, or dairy products.

Fully Automatic Lines

For water, soft drinks, and high-volume products requiring tens of thousands to hundreds of thousands BPH, complete bottling lines operate with full automation from start to finish, requiring minimal operator interaction with the production process.

Machine selection and technological level correlate directly with production speed and quality standards required throughout the cycle.

Critical Process: Filling to Capping

The most delicate phase in any bottling line is the filling-to-capping sequence. During this juncture, machines must prevent any contamination of the bottled product to maintain quality standards.

Contamination risks include:

• Oxidation — causes premature aging and quality degradation
• Bacterial contamination — can trigger acetic fermentation in wine, compromising drinkability
• Foreign particles — affect product safety and appearance

Proper precautions between filling and capping are essential for all food and beverage products to prevent irreversible quality deterioration.

Glass Bottling Lines

Glass bottle filling line composition varies based on several factors:

• Product type — still or carbonated beverages
• CO2 presence — affects filler technology selection
• Bottle destination — disposable or returnable cycle

Disposable Glass Bottling Lines

A disposable glass bottling line uses only new bottles destined for large-scale distribution, ending in recycling or disposal after consumer use. Key characteristics:

• Internal rinsing — various treatments ensure container sterility
• Simplified washing cycle — new bottles require no label removal or residue cleaning
• Optional bottle washer for complete internal and external cleaning
• Lower equipment investment compared to returnable systems

Returnable Glass Bottling Lines

Returnable bottling lines process glass bottles returned to the plant for reuse. This approach offers significant environmental benefits, saving approximately 80% of resources compared to single-use containers across the bottle lifecycle.

However, the bottling process becomes more complex, requiring additional specialized machines:

Returned bottles may arrive with or without caps, with or without labels, and containing internal residues. The pulp bottle washer restores bottles to original condition through caustic baths and multiple treatment stages, returning them to a state equivalent to new glass factory output.

While bottles can be reused multiple times, the cycle is not infinite — each bottle has a limited number of return cycles before retirement.

Container-Specific Line Differences

Complete bottling lines vary significantly based on container type:

• Glass bottles — require rinsers or washers, specific fillers, cork or cap closures
• PET bottles — may include blow molding, lighter handling systems, screw cap closures
• Cans — require seamers instead of cappers, different filling technology
• Cartons (Brik) — specialized forming, filling, and sealing equipment

Each container type involves different closure systems and process sequences, requiring specific machine configurations throughout the line.