 |
| Quantity: | |
|---|---|
This complete turnkey filling line is manufactured in strict alignment with national drinking water hygiene and food safety standards, with all product-contact surfaces constructed from premium food-grade 304/316 stainless steel. It consolidates every stage of 5-gallon water production into a single closed-loop system: automatic film cutting, cap removal, external barrel brushing, internal washing & sterilization, atmospheric filling, cap feeding & pressing, steam heat shrinking, light inspection, automatic bagging, gantry palletizing, and finished product conveying.
The entire production process runs in a fully enclosed configuration, paired with UV sterilization and ozone disinfection to effectively prevent secondary contamination during filling and meet sterile production requirements. All motion, detection, and control functions are managed by a Mitsubishi PLC system, which reduces fault rates, expands operational flexibility, and supports long, uninterrupted production runs.
Unlike sourcing equipment from multiple separate vendors, our single-source turnkey line delivers tangible value for your operation:
Customized line design tailored to your facility layout, production target, and product specifications, maximizing your return on investment with an optimal performance-to-cost ratio
End-to-end support from our experienced engineering team, from initial scheme design and equipment selection to on-site commissioning and operator training
Full compliance with drinking water and food hygiene standards across every component, fabrication process, and assembly step, with consistent, repeatable performance across every production shift
Seamless integration of all line stations by our in-house engineers, backed by responsive after-sales technical support
Unified technical coordination across the entire line, ensuring stable, accurate operation at full production speed with minimal manual intervention
Optional centralized real-time control and monitoring system for full visibility into line performance
Multi-language operation menu for intuitive use by global production teams
Mitsubishi PLC control system paired with high-sensitivity photoelectric detection for precise, responsive operation
Industry-leading performance-to-cost ratio for medium-capacity 5-gallon water production
Core electrical components sourced from reputable European, American, and Japanese brands for long-term durability
Comprehensive quality assurance system covering every stage from fabrication to final testing
Responsive after-sales support network with fast spare parts supply
Automatic full-line shutdown and fault alarm function for any station failure, preventing cascading production issues
Overall line production efficiency ≥ 99% under rated operating conditions
Full food-grade 304 stainless steel construction, with strict quality control over material thickness, welding finish, and fabrication quality
Totally enclosed original motors paired with premium industrial-grade water pumps
Mitsubishi PLC industrial control system for stable, programmable operation
Fully automatic barrel loading system for hands-free infeed
Automatic water flushing and drainage system with 3–5 bar rinsing pressure for thorough internal cleaning
Full set of 304 stainless steel pneumatic valves with imported pneumatic components
Fully automatic barrel washer with insulated closed fast reflux design for reduced energy consumption
Linear non-contact filling machine (atmospheric rotary filling available as an alternative configuration)
Integrated automatic cap feeding, sorting, placing and pressing system
Centrifugal cap sorting mechanism for steady, jam-free cap supply
Steam-type heat shrink tunnel with electronic detection for energy-efficient, uniform shrink results
Ultra-thin light guide panel light inspection station for easy visual quality checks
Automatic bagging machine to reduce labor requirements and energy use
Gantry palletizer to minimize manual heavy lifting and lower operator labor intensity
This production line consists of an adjustable single-head film cutting & decapping station, linear external barrel brushing machine, automatic barrel loader, internal washing & sterilization unit, filling system, cap feeding & pressing unit, intelligent steam heat shrink tunnel, and in-line light inspection station, all connected by a continuous conveying system for uninterrupted flow production.
Film Cutting & Decapping Station
Short-stroke, precision-driven dedicated cylinders deliver fast, accurate cap removal with simple on-site adjustment. The claw pieces are shaped to match the cap profile, preventing scuffs or damage to both barrels and caps during operation. The station features a simple, robust structure for easy routine maintenance.
Linear External Barrel Brushing Machine
All-around brushing and spraying process with center, side, and bottom brushes, all actively driven by gear transmission for thorough cleaning of the barrel neck, shoulder, body, and base. The wear-resistant design leaves no uncleaned dead spots, fully handling external washing to avoid cross-contamination between internal and external washing stations. It includes a dedicated lye washing station and offers easily adjustable production speed, with extremely high reliability and stability.
External-to-Internal Washing Transition
Linear conveying between the external brusher and internal washer delivers low energy consumption, precise positioning, and zero relative friction on the barrel base during transfer.
Internal Washing & Sterilization System
High-pressure rinsing process with industry-standard nozzle design, ensuring full coverage and no dead spots across the entire inner barrel surface.
Filling System
Available in linear non-contact filling or atmospheric rotary filling configurations, both compatible with 16–18.9L barrel formats to accommodate different product specifications.
Capping System
Centrifugal cap sorting mechanism with mature cap sorting and placing technology, compatible with barrel height variations of ±2cm. It features a stainless steel track-type cap pressing design for consistent, secure sealing across every barrel.
Intelligent Steam Heat Shrink Tunnel
The water tank connects directly to the municipal water supply, with a float-type electronic water level controller to maintain preset water levels. Electric heating elements heat the water, with pressure control circuits cutting power automatically once the adjustable 4–7 bar pressure setpoint is reached (warm-up takes approximately 10–20 minutes). With steam temperatures of 140–170°C, the fully automatic program-controlled system uses high-pressure steam storage for concentrated, efficient heat delivery, eliminating uneven shrinkage issues common in lower-end units.
Conveying System
Driven by imported gear reduction motors and paired with high-quality 304 stainless steel conveyor belts, ensuring high stability and reliable operation of the entire conveying system.
Full Stainless Steel Build
All main machine bodies are precision fabricated from high-quality food-grade SUS304 stainless steel for corrosion resistance, easy cleaning, and long service life.
Unified Control System
The entire line is controlled by a Mitsubishi industrial PLC system with stepless variable frequency speed regulation. Simple, intuitive operation ensures all functional stations work in tight, coordinated sync, supporting long hours of uninterrupted production.
For facilities looking for a reliable, cost-effective 5-gallon bottled water production solution, ZHONGZHENG provides full turnkey support including custom line design, on-site installation, operator training, and lifelong after-sales service. Contact our team to discuss your production requirements and receive a tailored project proposal.
