Aluminum Bottle 18000 to 36000bph High Speed Liquid Filling Machine

Product Description

Aluminum bottle filling machine 

1,Briefly describe the production process of the machine as follows: 

Bottles entering the three-in-one filling machine are separated by an infeed screw and then transferred to the bottle rinser via a bottle transfer star wheel. The rotary disc of the bottle rinser is equipped with bottle clamps, which grip the bottle mouth and flip it 180° along a guide rail to position the mouth downward. In a specific area of the bottle rinser, specialized nozzles spray rinsing water (sterile water) to disinfect (rinse) the inner wall of the bottle, while also disinfecting (rinse) the outer wall. After rinsing and draining, the bottle clamps flip the bottle 180° along the guide rail to return the mouth to an upward position. The cleaned bottles are then transferred out of the rinser via the bottle transfer star wheel and conveyed to the filler. Bottles entering the filler are lifted by bottle lifting cylinders, which move the bottles up and down under the action of a cam. During the lifting process, the bottles are first centered by centering cups on the valves. Continued upward movement brings the bottle mouth into contact with the valve, opening it to complete the filling process. After filling, the bottles descend and are transferred to the capper via a transition star wheel assembly. The capping process uses a hanging cap method, where the capping heads, under the action of a cam, perform edge pressing, thread screwing, and tamper-evident ring crimping to complete the entire capping process. The finished products are transferred from the capper to the outfeed conveyor chain via an outfeed star wheel and conveyed out of the three-in-one filling machine

Product Description

 Infeed mechanism:

The infeed method involves the coordinated action of the infeed screw and the bottle transfer star wheel.

Washing bottle mechanism

1.First, bottles are conveyed to the main unit via a conveyor chain. An infeed screw spaces the bottles at the required intervals for the main unit. The screw employs a variable-pitch design, with optimized spiral grooves to minimize surface damage to the bottles. A transition star wheel, synchronized with the screw, transfers the bottles into the bottle rinser. Inside the rinser, flip-type clamps grip the bottle necks and rotate 180° along a guide rail to invert the bottles mouth-down. When reaching the designated zone, nozzles spray cleaning fluid to thoroughly rinse both the interior and exterior surfaces. After drainage, the bottles rotate another 180° via the guide rail and are discharged by a transition star wheel to the next process.

 

a) Rotary disc: Fully welded with ANSI304 stainless steel.
b) Proprietary flip clamps: Patented design grips bottle necks, with ANSI304 stainless steel bodies for hygiene and durability.
c) High-efficiency nozzles: Spray cleaning fluid at calibrated angles to cover all interior surfaces, ensuring thorough rinsing with reduced water consumption.
d) Bearings: Flip mechanisms and sliding sleeves use German igus corrosion-resistant, maintenance-free bearings.
e)Drive system: Independently powered by servo motors.

2,Bottle transfer system

All bottle transfer star wheels and guard plates are made of SUS304 stainless steel, with mirror-polished surfaces on all bottle-contact areas to ensure no damage to the container surfaces.

Filling machine

The cleaned and sterilized bottles are transferred to the filling machine via a transition star wheel. At the handover station, a centering mechanism grips the bottle mouth to ensure alignment with the filling valve. The bottle then rises under the action of a bottle lifting cylinder, pressing the bottle mouth, centering cup, and filling valve sealing pad together. Simultaneously, the bottle mouth opens the mechanical filling valve to initiate filling. Air in the bottle escapes through a return channel into the return pipe. After filling is complete, the bottle lifting cylinder descends under the action of a lowering cam, concluding the entire filling process. The filled bottles are then discharged from the filling machine and proceed to the subsequent capping process.

a) The rotary disc is entirely made of ANSI304 stainless steel.

b) The filling valve, constructed from ANSI304 stainless steel, features a return channel and a rational structural design to ensure accurate filling volume.

c) The filling machine is independently powered by a servo-driven system.

Screwing cap mechanism

After filling, bottles are transferred to the capping machine via a transition star wheel. The capping process begins with a "hang-and-place" method, where caps are positioned onto the bottle mouths and aligned (for certain products, liquid nitrogen may be dripped onto the caps before placement). Once capped, the bottles enter the capping machine.

The capping assembly utilizes a dual-mechanical cam system:

The upper cam controls the vertical movement of the capping head. The lower cam governs the rotation, featuring a dual-thread sealing curve for two-stage cap tightening (ensuring secure sealing).The capping machine is driven by an external servo motor, which powers the capping gears, allowing adjustable rotation counts to accommodate different cap types from various manufacturers. This design ensures broad adaptability, meeting diverse production requirements while maintaining high precision and reliability.

When bottles enter the capping machine, the upper and lower cams work together to lower the capping assembly. The cap-forming punch head presses the cap to keep the bottle steady. Then, the lower cam controls the small capping cam to descend, tightening the thread and tamper-evident ring knives under spring pressure. As the main unit rotates, the capping head spins too, starting the thread-forming process. The lower cam ensures two-stage thread-forming for a perfect seal and neat cap threads.

After capping, bottles are transferred out of the three-in-one machine via a star wheel to the next step. To adjust the capping torque, just unscrew the capping head (it's easy to remove) and attach it to the included calibration tool. Use a torque wrench to set the force for all four capping knives precisely.

Triple-Equation Capping Cam Curve: 

Designed specifically for aluminum bottle capping, this cam profile uses a cubic equation to ensure smooth capping motion. It minimizes cam impact during operation, reduces wear on both the cam and moving components, and extends equipment lifespan. 

 

Dual-Stage Capping Technology: 

Addressing the deformation risks of aluminum caps/necks, this innovation replaces traditional single-stage capping with a two-step process. The control cam features dual capping curves: First stage (pre-forming): Applies reduced torque to gently initiate thread formation. Second stage (final shaping): Perfects seal integrity and visual appearance while controlling cap deformation. This approach guarantees leak-proof seals and aesthetic consistency.

Capping Servo Speed-Boost Technology:

The capping head's rotation is driven by servo-controlled gears. By programming servo parameters, the rotation speed can be precisely adjusted during the dual-stage camming process. This ensures optimal thread length for both sealing integrity and visual perfection.

 

Capping assembly frame description:

The capping assembly is mounted on a single-piece cast frame manufactured through a casting process. It moves vertically along linear guide rails under the control of mechanical cams, ensuring stability during capping (no radial wobble). The frame is made of ductile iron, which provides excellent mechanical strength and wear resistance for the rails, significantly extending the equipment's lifespan.

 

the lubrication system description:

The capping assembly features a comprehensive lubrication system with strategically placed oiling points. These allow effective lubrication of all rotating components and sliding surfaces of the guide blocks, ensuring smooth operation and reduced wear.

 

The spinning knives description:Long-life Spinning Knives

The spinning knives (thread-forming knife and tamper-evident ring-forming knife) are made from high-strength materials and enhanced with surface coating technology. This improves their hardness and smoothness, minimizing damage to the cap surface during the capping process.

 

High-Performance Spinning Knife Torque Spring:

The torque spring for spinning knives is made from imported music wire (SWPB material). It ensures stable and consistent torque output during capping, guaranteeing precise thread formation parameters. The SWPB material enhances durability and maintains uniform rotational force, critical for achieving leak-proof seals and perfect thread appearance.

 

Electrical list

Name	Brand	Name	Brand
Mainmotor(servo motor)	Inovance	Servo motor and control system	Inovance
Screw cap servo motor	Inovance	PLC	Inovance/Beckhoff
Reduce gear	Evergear	HIM	Weinview/Germany brand
pneumatic	SMC/Germany	frequency converter	Inovance
Lubricate bear	igus	Proximity electronic switch	SICK
Sealing	China	pneumatic	SMC
bear	China	Adjust pressure mechanism	Germany brand
Valve	China	air switch	Germany brand
Pump	China	motor protector	Germany brand
intermediate relay	Germany brand	contactor (switch)	Germany brand
open-phase safeguard	Germany brand	button	Germany brand
amphenol connector	Phoenix

Peiyu Enterprise wholly-owned below companies: Shanghai Peiyu Packaging technology Co, ltd, Anhui Peiyu Packaging technology Co,ltd. 
 
Through our long-term accumulated mechanical design and manufacturing experience, we currently have hundreds of mature and stable packaging machinery and equipment, including retorts, palletizer&depalletizer, loading& unloading machine, case packer,labeling machine, conveyor system etc. Peiyu'S intelligent machinery are mainly applied to food&beverage industry, condiment industry, wine industry, pharma, medical industry. We work together with Yili Group, Lulu Group, Weiwei Group, Hebei Y angyuan Company, Wong Lo Kat Group, Mengniu Group, Southern Black Seasame Group, Baoyin Can of Baosteel, Yinlu Chengdu, Yanghe Group, Bencao Heze, Jinyi Jilin, Zilin Vinegar, Jiyuan Youyang, UniPresident Enterprises, Ting Hsin Group, huapeng International Group Limited, Huiyuan Group,Unilever, Zhongya Hangzhou, Harbin Pharmaceutical Group, Qidu Pharmaceutical and many other famous enterprises. Also our products are exported to many foreign countries in North America, South America, Africa, Europe and the Middle East and maintain a high reputation in the market. We gain the title of "outstanding supplier " with our high quality products and services.
 
Peiyu establishes R&D centers in Xi an, Shanghai,Chuzhou,Continuously providing our clients with advanced technology.With the fomal production of our new manufacturing base 60,000m in Chuzhou,modern factory building, research and development center, processing center, testing center, assembly workshop, spare parts warehouse, office building,residential facilities, etc. Processing workshops is equiped Germany trulaser laser cutting machine, Plasma cutting equipment, HT Hision five surface machining center. American HAAS CNC, Laser cutting machine etc; for equipment manufacturing precision and stability provide a highly reliable guarantee. Peiyu strictly conforms to the ISO9001 quality management system to monitor the whole production process. We have also passed T V Certificate and CE Certificate. Peiyu adheres to the sustainable services and continuously pursues new business philosophy to make the most competitive intelligent equipments.

Specification