Application of Acrylic Material in Thermoforming
With the demand for diversified designs and the wide application of new materials, plastic materials are favored by designers and users because of their unique characteristics. There are many types of plastic materials, with obvious characteristics and wide applications, acrylic materials are undoubtedly the ones.
Ⅰ. Thermoforming
With the continuous development of science and technology, the manufacturing industry is also constantly innovating and progressing. Among them, thermoforming process, as an emerging manufacturing technology, is gradually becoming a new trend in the future manufacturing industry.
Thermoforming is divided into thin gauge thermoforming and heavy gauge thermoforming according to the thickness of the sheets.
Thermoforming is a plastic processing technology. The main principle is to heat a flat hard plastic sheet to soften it, then use vacuum to adsorb it to the surface of the mold, and then cool it into shape. It is widely used in plastic packaging, lighting, advertising, decoration and other industries.
Heavy gauge thermoforming refers to the use of materials with a thickness exceeding 2mm, which cannot be vacuum formed on fully automatic tools. A semi-automatic vacuum forming machine dedicated to thick gauge thermoforming must be used for processing and production.
To optimize the sheet forming process, it is crucial to consider various factors. Begin by carefully managing stress concentration heat sheet, ensuring that ambient air temperature is controlled. Achieve uniform temperature distribution across the sheet, paying particular attention to the sheet interior's cooling time. Use a proper mold covering to maintain forming temperature low. Employ a blowing mold consists of optical light sensors for precise monitoring. Alternatively, a jig or soft material can be utilized to enhance the cooling process. Implementing a horizontal heating system further contributes to the overall efficiency and effectiveness of the sheet forming operation.
Vacuum forming can be used for product design and manufacturing of rear-projection TV back covers, displays, medical equipment, textile machinery, automotive accessories, and product design and manufacturing in precision electronics, medical equipment, and cosmetics industries.
The main advantage of pressure forming is that it can produce complex shapes and sizes, while also providing supporting services during the manufacturing process, such as printing and assembly, to meet vacuum forming requires of different customers.
Ⅱ. Acrylic Sheet
Acrylic
Acrylic (PMMA) particles are colorless or transparent material with a specific gravity of 1.19 g/cm3 and low surface hardness. They are easily scratched by hard objects and difficult to catch fire. The melting point of PMMA is about 130–140°C, which is much lower than the high temperature of glass, which is about 1000 degrees.
The panel is coated with a high concentration of ultraviolet absorber. Acrylic has high transparency, can be weathered for a long time, never fade, has a service life of 5 to 8 years, and has good light transmittance, up to 93%, with excellent light transmittance and light soft.
Acrylic sheet is a plexiglass processed through a special process. It has strong hardness, good material, radiation protection, and good light absorption effect. With the development and widespread application of optical technology, it has gradually been widely used in industrial manufacturing and modern home life. middle. Moreover, acrylic materials have large sales volume and high recognition in the market.
PMMA has the advantages of being light, cheap, and easy to form. Its forming methods include casting, injection molding, machining, vacuum forming, etc. Injection molding, in particular, can be produced in large quantities with simple process and low cost. Therefore, its application is becoming more and more widespread, and it is widely used in instrument parts, automobile lights, optical lenses, transparent pipes, etc.
Why is Acrylic Sheet Suitable for Thermoforming?
Appearance
From the appearance point of view, acrylic sheets have the same transparency as crystal, with good light transmission effect, which can reach more than 93%. In the design and manufacturing process, many different colors can be customized according to requirements.
The dye effect is good. After a long period of There is no possibility of color fading after use. Only with good quality can it be widely promoted and used in the decoration process.
Good Processing Performance
It has excellent heat resistance. Generally speaking, the surface of its acrylic sheet has the advantage of very good resistance to high temperatures after encountering high temperatures. Of course, for different size ranges, they all need to be processed before they can be installed.
Its processing performance is relatively strong, and the quality and performance are the same as before processing. At the same time, it has good toughness and no defects will appear during the processing, the outdoor service life is about 5-10 years, and the color remains as new during use.
Production Process
In terms of the production process of acrylic sheets, there are mainly two types: casting type and extrusion type. The hardness and toughness of the sheet are improved through hot processing technology. This is why at the current stage, acrylic panels installed outdoors will not have any quality problems after a long period of weathering.
Therefore, the emergence of this new sheet material can have unique technical advantages from this process and form its own characteristics at the current stage.
Cast Plate: Higher molecular weight, excellent stiffness, strength and excellent chemical resistance. Therefore, it is more suitable for processing large-sized sign plaques, and the softening process takes a relatively long time.
This sheet is characterized by small batch processing, unmatched flexibility in color system and surface texture effects by other products, and complete product specifications, suitable for different needs.
Extruded plate: Compared with cast plate, extruded plate has lower molecular weight and weaker mechanical properties, but has higher flexibility, which is beneficial to bending and thermoforming processing, and its softening time is shorter. When processing larger-sized sheets, it is beneficial to various rapid vacuum forming.
At the same time, the thickness tolerance of extruded plates is smaller than that of cast plates. Since extruded boards are produced automatically in large batches, the colors and specifications are difficult to adjust, so the diversity of product specifications is subject to certain restrictions.
Translucency
In terms of appearance light transmission effect, there are mainly types such as transparent, translucent, milky white, etc. The colors are different, and the surface effects will also be different, and the visual impact is very strong.
Excellent Material
Acrylic sheet is a new green and environmentally friendly material in the 21st century. It has a high recycling rate and can be reused to make simple sheets. It has strong light transmittance. These characteristics make it play a key role in the decoration process.
Ⅲ. Application of Acrylic Thermoforming Products
In terms of engraving, decoration, handicraft production, advertising signs, light boxes, etc. PMMA has the advantages of being light, cheap, and easy to form.
Therefore, its application is becoming more and more widespread, and it is widely used in instrument parts, automobile lights, optical lenses, transparent pipes, etc.
In construction, it is mainly used in lighting bodies, roofs, sheds, stairs and interior wall panels. The application of acrylic in lighting lampshades and automotive lamps on highways and high-end roads is also quite rapid.
With the construction of hotels, guesthouses and high-end residences in big cities, lighting bodies have developed rapidly. Lighting bodies made of extruded plexiglass panels have the characteristics of high overall structural strength, light weight, high light transmittance and good safety performance. Compared with inorganic glass lighting devices, it has great advantages.
In terms of sanitary ware, acrylic can be used to make bathtubs, washbasins, dressing tables and other products. Acrylic bathtubs have been widely used due to their luxurious appearance, depth, easy cleaning, high strength, light weight and comfortable use.
Acrylic is the best new material for manufacturing sanitary ware after ceramics. Compared with traditional ceramic materials, in addition to its unparalleled high brightness, acrylic also has the following advantages:
It has good toughness and is not easy to be damaged, it has strong repairability. Just use soft foam and a little toothpaste to wipe the sanitary ware as new.
The texture is soft and does not feel cold and biting in winter.
The colors are bright and can meet the individual pursuits of different tastes.
Using acrylic to make basins, bathtubs, and toilets is not only exquisite in style and durable, but also environmentally friendly. Its radiation is almost the same as the radiation of the human body's own bones.
Acrylic can be made into various fashionable products, such as leather bags, waist chains, watches, high heels, heels, hair accessories, brooches, bracelets, buttons, earrings, necklaces, rings, pendants, photo frames, etc. There are many types and unlimited development space for continuation.
At the same time, acrylic material has high processing plasticity and good surface hardness and transparent luster. It is often used by designers to match with various materials in the design of various exquisite containers to add texture and practicality to the containers, such as lipsticks and Delicate containers such as chemicals, and other daily necessities such as massagers, jewelry boxes, fans, etc.
Taking advantage of the cool feeling of acrylic material and combining it with creative design, acrylic material is perfectly presented in a variety of popular boutiques.
Acrylic thermoformed door panel series: European style, Chinese style doors, door frames, dado panels, ceilings, gussets, etc.
Acrylic thermoformed curtain boxes, window sill panels, window covers, etc.
Acrylic thermoformed furniture series: desktops, benches, countertops, shelves, kitchens (bookcases, wardrobes), etc.
Acrylic thermoformed series production of various speakers.
Processing and production of acrylic thermoformed vehicles and special-shaped decorative products for boats.
Ⅳ. Advantages of Thermoformed Acrylic Products
Transparency
Colorless and transparent organic glass sheet with a light transmittance of over 92%.
Excellent Weather Resistance
It has strong adaptability to the natural environment. Even if it is exposed to sunlight, wind and rain for a long time, its performance will not change. It has good anti-aging performance and can be used outdoors with confidence.
Good Processing Performance
Suitable for both machining and vacuum forming, acrylic panels can be dyed, and the surface can be painted, screen-printed or vacuum coated.
Excellent Comprehensive Performance
Acrylic boards come in a wide variety of colors, and have extremely excellent comprehensive properties, providing designers with a variety of choices. Acrylic boards can be dyed, and the surface can be spray-painted, screen-printed or vacuum coated.
Non-toxic
It is harmless even if it comes into contact with people for a long time, and the gas generated when burned does not produce toxic gas.
Made of PMMA acrylic thermoforming, it has the characteristics of good light transmittance, bright and clean exterior and interior, environmental protection, and can be painted. The color can be changed to produce products of different specifications and shapes according to customer requirements.
Mainly used in plastic transparent covers of game consoles, lampshades, observation instrument covers, leisure furniture hammocks, organic handicrafts, bank signboards, advertising light boxes, etc.
Ⅴ. Precautions for Acrylic Thermoforming Production
General acrylic will undergo thermal deformation at about 100 degrees Celsius, so you must pay attention to this temperature when using it, and if it is to be used continuously, the temperature cannot be higher than 90 degrees.
When acrylic thermoformed products become blurry or unclean due to slight scratches or dust adsorption due to static electricity, you can use 1% soapy water to wipe them clean with a soft rag.
The hardness of the thermoformed surface is comparable to that of aluminum, so care should be taken to avoid scratching the surface when using or processing acrylic. If it is accidentally scratched, it will need to be restored by polishing.
When installing acrylic products, thermal expansion and contraction must be taken into consideration, and there must be a space for expansion and contraction during assembly.
If the preliminary processing work is not done well, the acrylic thermoformed product will also be deformed at the moment of demoulding, and the quality of the deformed product will inevitably be affected. In order to avoid similar problems from happening again, we must develop corresponding solutions to this problem.
In order to prevent deformation after pressure forming is demolded, the operator is first required to check the temperature of the cooling water, and at the same time adjust the water volume of the nozzle to meet the specified range. Secondly, the wind direction at each location must be adjusted to find the most suitable forming pressure for acrylic thermoforming production.
In addition, when demoulding, try to use the pressure of vibrating the upper mold to force smooth demoulding. If the air volume at the bottom can be appropriately increased, it will also be helpful to ensure the quality of acrylic thermoformed products. If these cannot solve the problem, the only way to overcome the deformation problem is to re-make the upper mold.
Conclusion
With the continuous advancement of social science and technology and the continuous improvement of process technology, acrylic thermoforming will have broader market prospects and application prospects in the future. Its future development trends include the following aspects:
1. Continuous improvement of creativity: As people pay more and more attention to personalization, acrylic thermoforming will use more creativity to create more unique products through different processes and materials.
2. More environmentally friendly and energy-saving: When making acrylic thermoforming products, low-carbon, environmentally friendly, and energy-saving methods will be increasingly used to achieve a greener production environment.
3. Upgrading of materials: As people pay more and more attention to health and environmental protection, acrylic blister materials will increasingly use healthy, environmentally friendly and safe materials, and improve the performance indicators of the materials through technical means.
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What Is Bottled Water Production Process Flow Chart
Written by: John
Checked by: Mark
June 28, 2024
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Table of Contents
What is The Bottled Water Production Flow Chart
Raw Water Sourcing and Pumping
Mechanical Filtration
Carbon Filtration
Reverse Osmosis (RO) System
Bottle Blowing
Bottle Washing and Sterilization
Filling and Capping
Inspection and Packaging
1) Raw water pump
2) Mechanical filter
3) Activated carbon filters
4) Water softener system
5) Precision filters
6) Reverse osmosis system
Types of Equipment
Maintenance and Considerations:
1) Air conveyor system
2) Water bottling machine
3) Cap feeder machine
4) Fully automatic bottle blow dryer
5) Laser coding machine
6) Self-adhesive labeler machine
Importance in Bottled Water Production
Types of Self-Adhesive Labeler Equipment
Maintenance and Considerations:
7) Shrink sleeve label machine
8) Shrink wrap machine
9) Pallet wrapping machine
1) Fully automatic bottle blow molding machine
2)Semi-automatic blow molder
3) Air compressor
4) Bottle blowing machine water chiller
5) Blowing machine air dryer
6) Air filter of bottle blowing machine
7) Mold temperature controller
8) Air storage tank of bottle blow molding machine
Conclusion
How many types of water bottling equipment are there?
The 9 Secrets To Effective BLOW MOULDER
Complete Production Process Flow Chart Of Bottled Water Production As Below
Section 1
Water Treatment
Raw Water Pump
Mechanical Filter
Activated Carbon Filters
Water softener system
Precision filters
Reverse osmosis system
Ozone system
UV light sterilizer
Section 2
Filling & Packaging
Air conveyor
Water bottling machine
Cap feeder machine
Bottle blow dryer
Laser coding machine
Self-adhesive labeler machine
Shrink sleeve label machine
Shrink wrap machine
Pallet wrapping machine
Section 3
Bottle Blowing
Automatic bottle blow molding machine
Semi-automatic blow molding machine
Air compressor
Water chiller
Air dryer
Air filter
Mold temperature controller
Air storage tankororCap FeederLight Inspection PanelBottle DryerSleeve Shrink LabelerShrink Wrapping Machine
Film Stretch Pallet Wrapper
Code Inkjet Printer
Mineral Water Filler
Auto bottle blower
Semi-auto bottle blowerSelf-adhesive LabelerOPP Hot Melt Labeleror
Water Storage Tank
RO water treatment system
High pressure compressor
Air storage tank
Air filter
air dryer
Air filter
water cooler
High pressure compressor
Air filter
air dryer
Air filter
Auto Unscrambler
Semi-auto Unscrambler
BOTTLE BLOWING SYSTEM
WATER TREATMENT SYSTEM
FILLING AND PACKAGING LINE
What is The Bottled Water Production Flow Chart
The production process of bottled water is comprehensive, involving multiple stages to ensure the highest quality and safety standards. This detailed guide covers each critical step, from water treatment to bottling and packaging, and finally to the blowing line and auxiliary equipment. Here’s an overview of the main steps:
Raw Water Sourcing and Pumping
The process begins with sourcing raw water, which is then pumped into the filtration system.
The raw water pump provides the necessary pressurization for the filtration equipment.
Mechanical Filtration
A mechanical filter removes impurities such as manganese, iron, and suspended particles larger than 20 microns.
This step helps to prepare the water for further purification.
Carbon Filtration
The carbon filter further purifies the water by removing organic compounds, chlorine, and other contaminants.
This stage helps to improve the taste and odor of the water.
Reverse Osmosis (RO) System
The RO system removes dissolved salts, minerals, and microorganisms, producing high-purity water.
This step ensures the water meets the required quality standards.
Bottle Blowing
The PET preforms are heated and then blown into the desired bottle shape using a blow molding machine.
The blow molding machine combines preform heating and bottle blowing in an automated process.
Precise control of parameters like stretching speed, pressure, and timing ensures proper material distribution and bottle quality.
Bottle Washing and Sterilization
The bottles are cleaned and disinfected before filling to ensure they are free from any contaminants.
Filling and Capping
The bottles are automatically filled and capped to maintain the integrity of the product.
Inspection and Packaging
The filled bottles are inspected for any defects.
The approved bottles are then packaged for distribution.
The entire production process is designed to ensure the safety and quality of the bottled water in compliance with relevant regulations.
01.
Water Treatment
1) Raw water pump
Description: The raw water pump is a critical component that provides the necessary pressure and flow for the pretreatment equipment and the reverse osmosis (RO) system.
Working Principle: The pump pressurizes incoming water to ensure a stable and sufficient inlet pressure for sand filters, carbon filters, and fine filters. This pressure must exceed the permeation resistance of the mechanical filters, enabling efficient water passage and providing a sufficient source for the RO system.
Key Functions:
Pressurizes raw water.
Ensures stable inlet pressure.
Overcomes permeation resistance.
Provides a reliable water supply for the RO system.
Applications: Bottled water production, municipal water treatment, industrial water purification, desalination and seawater treatment.
Importance in Bottled Water Production: Essential for the efficiency and effectiveness of the entire water treatment process, ensuring the quality and uniformity of the packaged water produced.
Types of Equipment:Equipment TypeDescriptionCentrifugal PumpCommonly used for raw water pressurization, providing high flow rates and moderate pressure.Positive Displacement PumpSuitable for high-pressure applications, such as RO systems.Submersible PumpInstalled directly in the water source, used for drawing water from wells or surface water.Booster PumpInstalled downstream of the pretreatment system to further increase pressure for the RO system.
Maintenance and Considerations:
Regular inspection and maintenance, including cleaning, lubrication, and impeller replacement.
Monitoring of pump performance, including flow rate, pressure, and energy consumption.
Proper sizing of the pump based on the system’s water demand and pressure requirements.
Ensuring the pump is compatible with the water quality and any potential corrosive or abrasive substances.
2) Mechanical filter
Description: Also known as the quartz sand filter, this multi-layered filtration device removes manganese, iron, heavy metals, silt, rust, colloidal matter, and suspended particles larger than 20 microns from raw water.
Working Principle: Performs backwashing and forward washing to ensure consistent water output and prolong equipment lifespan.
Key Functions:
Removes mechanical impurities, colloids, microorganisms, organic matter, and active chlorine from raw water.
Provides pre-treatment for downstream processes like reverse osmosis and ion exchange.
Improves water quality and extends the lifespan of water treatment systems.
Applications: Bottled water production, municipal water treatment, industrial water purification, surface and groundwater treatment.
Importance in Bottled Water Production: Vital in the pretreatment phase by removing turbidity, suspended solids, and other contaminants, ensuring the quality and consistency of the final product and protecting downstream equipment like RO membranes.
Types of Equipment:Equipment TypeDescriptionFilter CartridgePE, steel-lined rubber, steel-sprayed plastic, stainless steel, fiberglass-reinforced plastic.Filter MediaQuartz sand, activated carbon, manganese sand, anthracite.Filter ConfigurationSingle-flow, double-flow.
Maintenance and Considerations:
Regular backwashing and forward washing to maintain filter performance.
Monitoring pressure drop and turbidity levels to determine filter element replacement.
Proper selection of filter media based on water quality and treatment requirements.
Ensuring the filter is sized correctly to handle the system’s flow rate and water demand.
3) Activated carbon filters
Description: Activated carbon filters effectively remove residual chlorine, organic molecules, colloids, pigments, and heavy metal ions, ensuring water quality and extending downstream equipment lifespan.
Working Principle: Operate on the principle of adsorption, capturing contaminants on activated carbon particles.
Key Functions:
Removal of residual chlorine to protect downstream equipment.
Adsorption of organic molecules, colloids, pigments, and heavy metals.
Reduction of COD and SDI values to improve water quality.
Extending the lifespan of RO membranes and ion exchange resins.
Applications: Pretreatment for reverse osmosis and desalination systems, drinking water purification, industrial water treatment, wastewater treatment.
Importance in Bottled Water Production: Essential in the pretreatment process, ensuring the quality and safety of the final product while protecting the RO system and other downstream equipment.
Types of Equipment:Equipment TypeDescriptionCarbon TypePowdered activated carbon, granular activated carbon.Filter ConfigurationSingle-layer, multi-layer.Housing MaterialStainless steel, fiberglass-reinforced plastic.
Maintenance and Considerations:
Regular replacement of activated carbon and sponge layers.
Monitoring pressure drop and water quality to determine replacement frequency.
Proper cleaning of new activated carbon before installation.
Ensuring the filter is sized correctly to handle the system’s flow rate and water demand.
4) Water softener system
Description: The automatic water softener system removes hardness minerals, such as calcium and magnesium, through ion exchange.
Working Principle: It replaces calcium and magnesium ions with sodium ions, softening the water and preventing scale buildup in plumbing and equipment.
Key Functions:
Removes hardness minerals.
Prevents scale buildup.
Improves the efficiency and lifespan of reverse osmosis systems.
Applications: Residential and commercial water treatment, boiler and cooling tower water treatment, laundry and dishwashing applications, food and beverage processing.
Importance in Bottled Water Production: Maintains the quality and uniformity of the end product by preventing scale buildup in the RO system, extending membrane lifespan and improving water purification efficiency.
Types of Equipment:Equipment TypeDescriptionSoftening TankContains the ion exchange resin.ControllerManages system operation.Salt Tank and ValveProvides brine solution for resin regeneration.
Maintenance and Considerations:
Regular regeneration of the resin bed to maintain softening capacity.
Monitoring salt levels in the salt tank.
Periodic cleaning and maintenance of system components.
Proper sizing based on water usage and hardness levels.
5) Precision filters
Description: High-performance filtration devices that remove fine particles, impurities, and contaminants from various liquids using different filter elements.
Working Principle: Use various filter media and design processes to meet specific effluent water quality requirements, with filtration precisions ranging from 0.5 to 10 microns.
Key Functions:
Filtration, clarification, and purification of liquids.
Removal of fine particles, impurities, and contaminants.
Ensuring the safety and quality of downstream water and membrane elements.
Applications: Pharmaceutical, chemical, food and beverage industries, water treatment, brewing, petroleum, printing, and dyeing.
Importance in Bottled Water Production: Maintains the purity and safety of the final product by removing fine particles and contaminants, protecting downstream equipment like RO membranes.
Types of Equipment:Equipment TypeDescriptionFilter HousingPrimarily made of stainless steel (304 or 316), flange or clamp type.Filter ElementsPP meltblown, wire-wound, activated carbon, etc.Filter ConfigurationSingle or multiple elements, depending on processing capacity.
Maintenance and Considerations:
Regular replacement of filter elements based on usage and pressure drop.
Proper selection of filter media and precision based on application requirements.
Cleaning and maintenance of filter housing and components.
Monitoring flow rate, pressure drop, and effluent water quality.
6) Reverse osmosis system
Description: Highly effective water purification technology that uses selective permeation through a semi-permeable membrane to remove dissolved salts, colloids, microorganisms, and organic matter, producing high-purity water.
Working Principle: Uses a high-pressure pump to force raw water through the RO membrane, allowing only water molecules to pass through while retaining other contaminants.
Key Functions:
Removes dissolved salts and impurities.
Produces high-purity water.
Energy-efficient and low-pollution technology.
Applications: Bottled water production, pharmaceutical and electronics manufacturing, seawater and brackish water desalination, industrial water purification.
Importance in Bottled Water Production: Ensures the quality and safety of the final product by eliminating various impurities, adhering to strict industry standards.
Types of Equipment
RO Membrane TypeDescriptionBrackish Water RO (BWRO)– Used for feedwaters with relatively low total dissolved solids (TDS) compared to seawater – Require lower operating pressure (125-250 psi) – Maintain high salt rejection (>95-99%) – Typical recovery rates of ≥75%Seawater RO (SWRO)– Used for seawater or feedwaters with high TDS (35,000 mg/L or greater) – Require much higher operating pressure (800-1200 psi) – Maintain very high salt rejection (>99.5%) – Typical recovery rates of 50-70%Nanofiltration (NF)– Similar to RO but has lower rejection of monovalent ions like sodium chloride – Highly effective at rejecting divalent ions like magnesium sulfate (>97%) – Also rejects organic macromolecules to varying degrees – Operates at lower pressures than traditional RO membranesThin-Film Composite (TFC)– Most common type of industrial RO membrane – Consists of a polyamide top barrier layer, polysulfone support layer, and polyester layer – Prevents molecules greater than 100 molecular weight from passing throughCellulose Triacetate (CTA)– Alternative to TFC membranes – More resistant to chlorine but less effective at salt rejection
This table covers the key characteristics and applications of the main types of industrial RO membranes, including brackish water, seawater, nanofiltration, and the common membrane materials used (TFC and CTA).
Maintenance and Considerations:
Regular cleaning and maintenance of the RO membrane to prevent fouling and scaling.
Monitoring water quality parameters such as TDS, conductivity, and SDI.
Proper selection of membrane elements based on raw water characteristics and production needs.
Ensuring the RO system is sized correctly to handle the required water flow and quality.
02.
Filling & Packaging
1) Air conveyor system
Description: Uses fan-generated wind energy to transport empty PET containers from the bottle blowing machine to the filling or labeling machine.
Working Principle: Wind energy propels the containers through ducts with air storage capabilities, ensuring a stable and continuous flow.
Key Functions:
Efficient transportation of empty PET containers.
Compatibility with high-speed filling and labeling machines.
Gentle handling of containers to prevent damage.
Flexible layout options for horizontal, vertical, and curved conveyance.
Applications: Bottled water and beverage production, industries requiring the transportation of empty PET containers.
Types of Equipment:Equipment TypeDescriptionFan Power UnitProvides the wind energy for bottle conveyance.Air DuctStraight, turning, and up-and-down sections made of 304 stainless steel.Bottle Handling DevicesDividing, merging, and dropping mechanisms.Bottle Clamping DevicesEnsures stable bottle transport.
Maintenance and Considerations:
Regular cleaning and inspection of the air duct and bottle handling components.
Monitoring the fan performance and airflow to maintain optimal conveyor operation.
Adjustments to accommodate changes in bottle size or production requirements.
Ensuring the system is properly integrated with the overall bottling line.
2) Water bottling machine
Description: The PET water filling machine automates washing, filling, capping, and other functions with high precision, using advanced electrical components and high-quality stainless steel parts.
Working Principle: A suspended filling equipment design allows operation with various bottle types, sizes, and thicknesses, controlled automatically.
Key Functions:
Bottle rinsing.
Bottle filling.
Screw capping.
Cap sorting.
Applications: Filling production of 200-2000ml PET water bottles, suitable for a wide range of bottle types and sizes.
Types of Equipment:Machine TypeDescriptionLiquid Bottling MachinesDesigned to bottle liquids, including water, using volume or weight measurement to fill bottles.Rotary Bottling MachinesHave a rotary design where bottles move in a circular motion through the filling, capping, and sealing process.Linear Bottling MachinesHave a linear design where bottles move in a straight line through the different filling, capping, and sealing stations.Fully Automatic Bottling MachinesAutomate the entire bottling process from bottle rinsing to capping, requiring only a few operators.Semi-Automatic Bottling MachinesRequire more manual operation, with steps like bottle loading and unloading done by workers.Gravity, Pressure, and Vacuum Overflow Bottle FillersSpecific types of liquid filling mechanisms used in water bottling machines.Pump FillersAnother type of liquid filling mechanism used in water bottling machines.
Maintenance and Considerations:
Regular cleaning and maintenance of the filling valves and other components in contact with water.
Proper adjustment and calibration of the bottle handling and capping mechanisms.
Monitoring and addressing any issues with the electrical and control systems.
Ensuring the availability of spare parts and trained technicians for timely repairs.
3) Cap feeder machine
Description: The cap feeder machine sorts and feeds caps automatically, using standardized and interchangeable parts.
Working Principle: It arranges caps using their center of gravity, ensuring smooth output.
Key Functions:
Automatic cap feeding and arrangement.
Automatic cap removal.
Applications: Can be used with three-in-one filling machines or separate capping machines, suitable for various types of caps.
Types of Equipment:Equipment TypeDescriptionThree-Screw Cap Sorting and Capping MachineDesigned based on the characteristics of three-screw caps, with different weights on both sides.Other Capping MachinesCan be provided for plastic screw caps, aluminum caps, crown caps, and other capping applications.
Maintenance and Considerations:
Regular cleaning and maintenance of the cap sorting and feeding mechanisms.
Monitoring and addressing any issues with the electrical and control systems.
Ensuring the availability of spare parts and trained technicians for timely repairs.
Adjusting the production capacity based on the specifications and characteristics of the product.
4) Fully automatic bottle blow dryer
Description: The blow dryer uses high-pressure air to dry water droplets on bottle surfaces, preparing them for subsequent processing steps like coding and labeling.
Working Principle: It uses wind instead of high temperature, suitable for plastic bottles that are not heat-resistant.
Key Functions:
Dries water droplets using high-pressure air.
Facilitates coding, labeling, and packaging.
Applications: Suitable for drying various types of plastic bottles, can be used in water bottling production lines.
Components of Equipment:ComponentDescriptionAir KnifeGenerates high-pressure air flow to dry the bottles.Vortex FansHigh-powered vortex fans produce the necessary air volume.FrameMade of stainless steel and glass, providing a sturdy structure.Heating SystemHigh-pressure vortex pump generates heat during operation.Electrical ControlsIncludes control box for easy operation and monitoring.ConveyorAutomatically feeds the containers through the drying chamber.SensorsDetect the presence of containers and control the drying cycle.
Maintenance and Considerations:
Regular cleaning and maintenance of the air knives and air intake/exhaust components.
Monitoring and addressing any issues with the electrical and control systems.
Ensuring the availability of spare parts and trained technicians for timely repairs.
Adjusting the air knife positioning and airflow based on the bottle dimensions and drying requirements.
5) Laser coding machine
Description: The laser coding machine applies high-quality, permanent text, logos, and barcodes onto bottles and packaging materials.
Working Principle: A focused beam of light precisely etches or marks the desired information onto the target surface.
Key Functions:
Applies text, logos, and barcodes.
Provides high-resolution, permanent markings.
Applications: Bottled water production, canned and packaged food and beverages, pharmaceutical and medical device packaging, consumer electronics and industrial product labeling.
Types of Equipment:Equipment TypeDescriptionCO2 Laser CodersUse a carbon dioxide laser to mark on a variety of materials, including plastic, glass, and metal.Fiber Laser CodersEmploy a fiber-optic laser for high-speed, high-contrast coding on a wide range of substrates.UV Laser CodersUtilize ultraviolet laser technology to mark on sensitive materials like plastics and films.Hybrid Laser CodersCombine multiple laser technologies to offer versatile coding capabilities.
Maintenance and Considerations:
Regular cleaning and maintenance of the laser optics and components.
Proper alignment and calibration of the laser system.
Ensuring adequate ventilation and cooling for the laser unit.
Adherence to safety protocols and guidelines for laser operation.
Consideration of substrate compatibility and pre-treatment requirements.
6) Self-adhesive labeler machine
Description: The self-adhesive labeler machine automates label application onto bottles with high precision.
Working Principle: It uses mechanical, electrical, and software components to align and apply labels accurately.
Key Functions:
Accurate label positioning and alignment.
High-speed label application.
Adjustable label size and placement.
Applications: Bottled water production, beverage bottling, personal care and cosmetic products, pharmaceutical packaging.
Importance in Bottled Water Production
In the containerd water industry, the self-adhesive labeler machine plays a crucial role in ensuring consistent, high-quality labeling of containers. Accurate and efficient label application enhances the visual appeal of the product, reinforces brand identity, and provides important information to consumers.
Types of Self-Adhesive Labeler Equipment
EquipmentDescriptionRotary LabelerApplies labels to containers as they rotate on a turntableIn-Line LabelerApplies labels to bottles moving along a conveyor beltWrap-Around LabelerApplies labels that wrap around the entire bottle circumferencePrint-and-Apply LabelerIntegrates label printing and application in a single machine
Maintenance and Considerations:
Regular cleaning and maintenance of label feeding and application components.
Ensuring proper label stock compatibility and quality.
Monitoring label alignment and adjusting as needed.
Implementing preventive maintenance schedules.
Training operators on proper machine operation and troubleshooting.
7) Shrink sleeve label machine
Description: The shrink sleeve label machine applies and shrinks sleeve labels onto bottles, providing 360-degree coverage and enhanced branding opportunities.
Working Principle: Bottles are fed into the machine, where pre-cut sleeve labels are positioned and heat-shrunk onto the bottle surfaces.
Key Functions:
Accurate sleeve label positioning and alignment.
Precise heat application for shrinking labels.
Adjustable label size and bottle diameter compatibility.
Integrated label feeding and application.
Seamless integration with bottling line.
Applications: Bottled water production, beverage bottling, personal care and cosmetic products, pharmaceutical packaging.
Types of Equipment:Equipment TypeDescriptionContinuous Motion Shrink Sleeve LabelerApplies labels to bottles moving on a conveyor belt.Intermittent Motion Shrink Sleeve LabelerApplies labels to stationary bottles.Sleeve ApplicatorApplies pre-cut sleeve labels onto bottles.Shrink TunnelProvides controlled heat to shrink and secure sleeve labels.
Maintenance and Considerations:
Regular cleaning and maintenance of label feeding and application components.
Ensuring proper label stock compatibility and quality.
Monitoring label alignment and adjusting as needed.
Maintaining optimal heat settings for effective shrinking.
Implementing preventive maintenance schedules.
Training operators on proper machine operation and troubleshooting.
8) Shrink wrap machine
Description: The shrink wrap machine wraps bottled beverages in shrink film, using a constant temperature PE shrinking furnace to achieve the packaging effect.
Working Principle: The machine uses steel and stainless steel components with a compact design, incorporating electrical and pneumatic components from renowned brands for efficient operation.
Key Functions:
Automatic wrapping, sealing, cutting, heat shrinking, and cooling.
Suitable for shrink films like PE and PVC.
Provides a neat, compact, and secure packaging of the bottles.
Applications: Packaging of bottled beverages such as purified water and mineral water, cans and glass bottles, various food, pharmaceutical, and chemical products.
Types of Equipment:Machine TypeDescriptionThroughputSuitable ProductsAutomatic Bottle Stack Sleeve Shrink Wrapping MachineDesigned for automatic bottle stacking, film feeding, sealing, and shrinking.8-30 bottles/minuteBottles, cans, glass bottlesContinuous Motion Shrink Wrapping MachineUses a direct feeding method with no length limit for packaged items.Up to 120 bottles/minuteLong-length objects, beverages, beer, mineral water, cans, glass bottlesSemi-Automatic Shrink Wrapper with Shrink TunnelProvides a reliable solution for high-quality shrink-wrapped packs.10,800 bottles/hourBottles, cans, and other containersIntermittent Motion Tray Shrink Wrapper with Integral Shrink TunnelSuitable for wrapping bottles, cans, and other containers on a tray or with a cardboard pad.6-20 bottles/minuteCylindrical, flat, square, and complex-shaped containers
Maintenance and Considerations:
Regular maintenance of the machine components, including cleaning and lubrication.
Proper storage and handling of the shrink film to ensure its quality and performance.
Monitoring of the temperature and air circulation in the shrinking furnace to ensure consistent and effective shrinking.
Adjusting the machine settings to accommodate different bottle sizes and packaging requirements.
Ensuring the proper alignment and functioning of the conveyor belt and bottle separating board.
9) Pallet wrapping machine
Description: The pallet wrapping machine wraps goods stacked on pallets with LLDPE stretch film, providing stability, protection, and waterproofing during storage and transportation.
Working Principle: Controlled by a PLC programmable controller, it offers adjustable film tension, automatic photoelectric tracking, and multifunctional packaging modes.
Key Functions:
Automatic wrapping of palletized goods.
Adjustable film tension for optimized packaging.
Partially enhanced wrapping for reinforced top/bottom.
Manual/automatic switching and automatic protection.
Multifunctional packaging modes (standard, quasi, single-layer, enhanced).
Automatic reset to initial position after each use.
Dynamic pre-stretching film frame system.
Applications: Food and beverage production, irrigation equipment, paper manufacturing, dyes and chemicals, glass and ceramics, electro-mechanical castings.
Types of Equipment:Equipment TypeDescriptionTray-type Pallet Wrapping MachineWraps palletized goods using LLDPE stretch film.Top-pressure Resistance-stretch Pallet Wrapping MachineApplies top pressure during wrapping.Pre-tension Automatic Pallet Wrapping MachineAutomatically pre-tensions the stretch film.
Maintenance and Considerations:
Regular inspection and maintenance of machine components.
Proper storage and handling of stretch film.
Monitoring of film tension and wrapping patterns.
Adjusting settings for different pallet sizes and products.
Ensuring proper alignment of sensors and lifting mechanisms.
Maintaining a clean work environment.
03.
Blowing Line
1) Fully automatic bottle blow molding machine
Description: The fully automatic bottle blow molding machine is used to blow all kinds of plastic containers and beverage bottles using PET raw material.
Working Principle: The machine features a user-friendly interface, smooth operation, high and stable output, low energy consumption, and a high degree of automation. It uses a double toggle and primary link hinge mechanism with solid clamping force for stable and reliable blowing action.
Key Functions:
Automatic preform loading and feeding.
Precise temperature control and even heating of preforms.
Stable and fast mold clamping and bottle blowing.
Automatic bottle ejection and transfer to filling machine.
Integrated PLC control with automatic fault detection.
Applications: Production of water bottles, juice, soda, and other beverage bottles, plastic containers for food, cosmetics, and household products.
Types of Equipment:Machine TypeDescriptionLinear Stretch Blow Molding MachineUses linear motion to stretch and blow preforms into bottles. Cost-effective with a good balance of production speed and quality.Rotary Stretch Blow Molding MachineUses rotary motion to stretch and blow preforms. Faster production speed compared to linear machines. Can achieve higher quality bottles.
Maintenance and Considerations:
Regular inspection and maintenance of mold clamping, heating, and blowing components.
Proper storage and handling of the preform raw material.
Monitoring temperature control system and energy consumption.
Adjusting machine settings for different bottle sizes and production requirements.
Ensuring proper alignment and functioning of automatic feeding, ejection, and transfer systems.
2)Semi-automatic blow molder
Description: Semi-automatic blow molding machines are versatile equipment used for producing a variety of plastic bottles and containers.
Working Principle: These machines use a combination of manual and automated processes to blow mold plastic preforms into the desired bottle shapes.
Key Functions:
Preform heating and softening.
Mold clamping and bottle blowing.
Bottle ejection and trimming.
Applications: Beverage bottles (water, juice, soda, etc.), personal care bottles (shampoo, lotion, etc.), household chemical containers, pharmaceutical packaging.
Types of Equipment:FeatureManual Preform LoadingAutomated Preform LoadingPreform LoadingManual hand-feedingAutomatic preform insertionBottle RemovalManual removalManual removalEfficiencyLowHigherLabor Required1-2 workers1 workerCostVery lowModeratePreform HandlingRequires gloves for hot preformsAutomated preform handling
Maintenance and Considerations:
Regular cleaning and maintenance of molds and machine components.
Proper temperature and pressure control for consistent bottle quality.
Operator training for safe and efficient machine operation.
Consideration of energy efficiency and environmental impact.
3) Air compressor
Description: An air compressor converts power into potential energy stored in pressurized air.
Working Principle: It works by drawing in ambient air, compressing it to a higher pressure, and discharging the compressed air for various applications.
Key Functions:
Intake and compression of air.
Storage of compressed air.
Delivery of compressed air to end-use applications.
Applications: Powering pneumatic tools and equipment, inflating tires, spray painting, cleaning and drying, controlling and operating industrial machinery.
TypeDescriptionReciprocatingPiston-driven compressors that use a back-and-forth motion to compress air.Rotary ScrewUse two meshing helical screws to draw in and compress air.CentrifugalUse rotating impellers to draw in and accelerate air, increasing pressure.ScrollUse two spiral-shaped scrolls to compress air in a continuous process.
Maintenance and Considerations:
Regular filter and oil changes.
Monitoring for air leaks.
Proper sizing and selection for the application.
Ensuring adequate cooling and ventilation.
Adhering to safety protocols when operating.
4) Bottle blowing machine water chiller
Description: A water chiller regulates the temperature of the water used in the bottle blowing process.
Working Principle: The chiller circulates water through the bottle blowing mold to maintain a consistent temperature, ensuring proper formation and cooling of the plastic bottles.
Key Functions:
Temperature regulation of the bottle blowing mold.
Consistent cooling of the molded plastic bottles.
Efficient heat transfer from the hot mold to the circulating water.
Applications: Bottle blowing in PET, HDPE, and other plastic bottle production, cooling of molds in injection molding and extrusion blow molding processes, temperature control in various industrial cooling applications.
Types of Equipment:TypeDescriptionRecirculating ChillerContinuously circulates and cools a closed-loop water system.Inline ChillerCools water as it flows through the system, without a closed loop.Portable ChillerSelf-contained, mobile units for temporary or flexible cooling needs.Integrated ChillerBuilt-in to the bottle blowing machine for a compact, all-in-one solution.
Maintenance and Considerations:
Regular cleaning and maintenance of the water system.
Monitoring and adjusting water temperature and flow rate.
Ensuring proper ventilation and heat dissipation.
Adhering to manufacturer’s recommendations for maintenance and service intervals.
Considering the cooling capacity and efficiency requirements for the specific bottle blowing application.
5) Blowing machine air dryer
Description: An air dryer removes moisture from the compressed air used in the bottle blowing process.
Working Principle: The air dryer uses various drying techniques, such as refrigeration or desiccant adsorption, to reduce the moisture content of the compressed air before it is used in the bottle blowing mold.
Key Functions:
Removal of water vapor from compressed air.
Preventing condensation and moisture buildup in the bottle blowing system.
Ensuring a consistent, dry air supply for the blowing process.
Applications: Bottle blowing in PET, HDPE, and other plastic bottle production, drying of compressed air for various industrial processes, preventing moisture-related issues in pneumatic equipment and tools.
Types of Air Dryers:TypeDescriptionRefrigerant DryerUses refrigeration to cool the air and condense water vapor.Desiccant DryerUtilizes a desiccant material to adsorb moisture from the air.Membrane DryerEmploys a semi-permeable membrane to selectively remove water vapor.Heatless DryerRegenerates the desiccant using a portion of the dried air.
Maintenance and Considerations:
Regular cleaning and replacement of filters and desiccant materials.
Monitoring and adjusting air flow and pressure.
Ensuring proper ventilation and heat dissipation.
Adhering to manufacturer’s recommendations for maintenance and service intervals.
Considering the air flow and drying capacity requirements for the specific bottle blowing application.
6) Air filter of bottle blowing machine
Description: An air filter removes contaminants such as dust, oil, and moisture from the compressed air stream.
Working Principle: The air filter uses a combination of mechanical filtration, coalescence, and gravity separation to capture and remove harmful particles and liquids from the compressed air.
Key Functions:
Removal of solid particulates (dust, rust, etc.).
Separation of liquid water and oil droplets.
Providing clean, dry compressed air for downstream equipment.
Applications: Compressed air systems in industrial facilities, pneumatic tools and equipment, instrument air systems, bottling and packaging machinery, painting and coating applications.
Types of Air Filters:TypeDescriptionCoalescing FilterRemoves liquid water and oil droplets through coalescence.Particulate FilterCaptures solid particulates such as dust and rust.Combination FilterIntegrates both coalescing and particulate filtration.Desiccant FilterRemoves water vapor through adsorption on a desiccant material.
Maintenance and Considerations:
Regular inspection and replacement of filter elements.
Monitoring pressure drop across the filter.
Proper drainage of collected liquids.
Ensuring adequate air flow and system compatibility.
Adhering to manufacturer’s recommendations for maintenance and service intervals.
7) Mold temperature controller
Description: A mold temperature controller regulates the temperature of the mold in the bottle blowing process, ensuring proper appearance and quality of the final plastic bottles.
Working Principle: It maintains the mold at a constant, optimal temperature to prevent defects such as lack of gloss, deformation, bubbles, and uneven wall thickness.
Key Functions:
Precise temperature control and fast heating/cooling response.
Stable and accurate temperature maintenance within ±1°C.
Automatic temperature regulation and monitoring.
Liquid level alarm to prevent damage from low heat transfer fluid.
Applications: Plastic bottle manufacturing, other blow molding processes for plastic products.
Types of Equipment:EquipmentFeaturesHorizontal High-Temperature Resistant PumpStable flow, reliable performance.Stainless Steel Pipelines and Fuel TanksRust-resistant, long service life.Visualized Heat Transfer Oil Level TubeEasy to monitor oil level.Brand-Name Components (Omron, Fuji, LG, Schneider)Excellent performance, long lifespan.Imported Heating ComponentsSuperior quality and durability.
Maintenance and Considerations:
Regularly check and maintain the heat transfer fluid level.
Ensure proper insulation of pipelines to minimize heat loss.
Perform periodic cleaning and inspection of system components.
Monitor temperature control accuracy and make adjustments as needed.
Properly store and handle the heat transfer fluid to prevent contamination.
8) Air storage tank of bottle blow molding machine
Description: The air storage tank stores compressed air generated by the air compressor and provides a consistent and controlled supply of compressed air for the bottle blow molding process.
Working Principle: The tank stores pressurized air and releases it as needed to inflate the preform during the blow molding stage, shaping the bottle.
Key Functions:
Stores compressed air.
Ensures a consistent and reliable air supply.
Regulates air pressure and flow to the blow mold.
Applications: Bottle blow molding for water, beverages, and other liquid products, plastic container manufacturing, hollow plastic part production.
Types of Equipment:Equipment TypeDescriptionVertical Air Storage TankCompact design, suitable for limited space.Horizontal Air Storage TankLarger capacity, suitable for high-volume production.Stainless Steel Air Storage TankDurable, corrosion-resistant, suitable for food-grade applications.Aluminum Air Storage TankLightweight, suitable for mobile or portable applications.
Maintenance and Considerations:
Regular inspection and cleaning of the tank to prevent contamination.
Monitoring and maintaining proper air pressure levels.
Checking for leaks and ensuring airtight seals.
Replacing worn or damaged components as needed.
Adhering to the manufacturer’s recommended maintenance schedule.
04.
Conclusion
The production process of bottled water involves several intricate steps, from initial water treatment through bottling, packaging, and bottle blowing. Each stage requires specific equipment, regular maintenance, and careful monitoring to ensure the highest quality and safety standards are met. By following this detailed process flow, you can ensure efficient and effective bottled water production, meeting industry standards and consumer expectations.
For more detailed information, expert assistance, or to get quotes for your specific bottled water filling needs, feel free to get in touch with us through the contact form provided. We are here to help you achieve the best results in your bottled water production endeavors.
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