4 Types of Essential Packaging Machines for Bottled Milk Drink Automated Production

After picking up Danone drinks like the Actimel 4-pack or 8-pack from the supermarket shelf, you might wonder how these beverages are produced and packaged in such attractive retail designs, including the cardboard packaging that holds multiple units.

To truly understand this, it’s important to go beyond the perspective of an average consumer with limited knowledge of the beverage industry and explore the manufacturing and packaging processes that bring these products to grocery store shelves.

In this article, we’ll explore the milk drink production process and introduce the various packaging machines and equipment that have automated the manufacturing of the drinks you enjoy.

Bottle Descrambler (Unscrambler)

Running dairy bottles in the most upfront part of a milk drink production and packaging line is frequently a bottle unscrambler that feeds the equipment in the latter sections of the line with pre-formed empty bottles in an aligned and timed manner.

A bottle unscrambler plays a crucial role in the bottle filling and packaging process for dairy products like 16-ounce HDPE bottles. Its main function is to efficiently orient bottles into a uniform position, ensuring they are ready for downstream processes in the filling line, regardless of how they enter the machine.

Working Principle of Bottle Descrambler

• Rotating Disk and Centrifugal Force: The bottles enter a rotating disk where centrifugal force pushes them outward. This process randomly positions the bottles either neck-first or base-first (neck-leading or base-leading).
• Rotary Bumper: If a bottle is misaligned, it is knocked back into the disk by a rotary bumper for re-alignment. This ensures that only bottles in the correct orientation proceed.
• Infeed Tooling and Hook Mechanism: Bottles that are either neck-leading or base-leading are captured by an infeed belt. Neck-leading bottles are hooked and flipped into a base-leading position. Base-leading bottles bypass the hook and continue along the path.
• Stabilization and Exit: Once in the correct orientation (base-leading), bottles are stabilized and sent to the next conveyor, ensuring they are upright and properly aligned for the filling and packaging stages.

Structure of the Machine of Bottle Descrambler

• Rotating Disk: The main component where bottles are spun and sorted.
• Rotary Bumper: Adjusts misaligned bottles to ensure proper positioning.
• Infeed Belt and Hook: Mechanisms responsible for capturing and reorienting the bottles.
• Stabilization Zone: Ensures the bottles are securely positioned for transfer to the next conveyor.
• Customer’s Conveyor: After unscrambling, the bottles are transferred to the conveyor for the next stage in the production line.

Filling Machine & Capping Machine

A more effective way to explain what a filling and capping machine is and how it works is by referencing specific equipment from manufacturers, such as the Dynafill by Krones.

The Dynafill is a cutting-edge machine designed for the efficient filling and capping of bottles in a single, streamlined process. It is particularly suitable for high-speed bottling lines, such as those used in the dairy industry for bottled milk. The machine’s innovative design significantly reduces both space and energy consumption while increasing output and product quality.

Working Principle

• Filling and Capping in One Unit: The Dynafill combines both the filling and capping functions into a single machine. Unlike conventional systems where filling and capping are separate steps requiring separate machines, this design significantly reduces the time and space needed for the process.
• Speed and Efficiency:
  • The filling process takes only about 0.5 seconds per bottle.
  • The entire filling and capping process is completed in around 5 seconds.
  • The machine can process up to 80,000 containers per hour, drastically increasing throughput.
• Temperature Flexibility: The Dynafill can handle filling at temperatures up to 30 °C, which reduces the need for cooling energy. This flexibility makes it suitable for both cold and warm fill processes, depending on the product requirements.
• Microbiological Safety: The closed design of the filling and capping unit minimizes exposure to contaminants, reducing microbiological risks during the filling process. This ensures that products like milk remain pure and safe.
• Energy Efficiency: By using innovative technology, the Dynafill reduces CO2 consumption by 20% compared to traditional systems. Additionally, it utilizes the released cooling energy elsewhere in the production process, contributing to overall energy savings.
• Reduced Footprint: The machine’s 2-in-1 filling and capping design significantly reduces the required space. Since the bottles are already capped when they leave the machine, there is no need for a separate section on the conveyor to empty uncapped bottles. This leads to a smaller overall line footprint.

Structure

• Filling and Capping Head: The core component of the machine is a combined filling and capping head, which handles both operations simultaneously. The head is part of a closed, hygienic system that prevents contamination and ensures product purity.
• MultiGuide Base Clamping Starwheels: These versatile starwheels handle different bottle sizes and formats without the need for extensive changeovers. They enable the fast and efficient transfer of bottles through the filling and capping stages.
• Decentralized Electronics: To reduce the size of the control system, the power supply for the electronics is integrated directly into the filling valves. This eliminates the need for large control cabinets, further reducing the machine’s footprint.
• CIP Integration: The entire filling and capping area is part of a Clean-in-Place (CIP) system, allowing the machine to be easily cleaned and maintained without disassembly. This feature ensures consistent hygiene and product quality, which is especially important in food and beverage applications like milk bottling.
• Reduced Space for Buffer Section: Since the bottles are capped immediately after filling, the usual buffer section required for transporting uncapped bottles to a separate capper is no longer necessary. This enables the integration of a compact conveyor system and allows for innovative line layouts in production facilities.

The Dynafill significantly boosts output by processing up to 80,000 bottles per hour, making it one of the fastest machines for liquid bottling lines. Its ability to fill at warmer temperatures reduces the need for cooling, leading to lower energy consumption. The closed system design minimizes contamination risks, ensuring high hygiene standards for sensitive products like milk. Additionally, its compact design saves valuable floor space in production facilities.

Labelling Machine

A high-speed labeling machine for milk drink bottles enhances production efficiency by applying labels with precision at a rate of up to 50,000 bottles per hour. It ensures consistent label placement, reducing errors and waste. The machine’s flexible design accommodates various bottle shapes and sizes, making it suitable for different product lines. Its automatic label roll changeover minimizes downtime, ensuring continuous operation.

With a compact footprint, it optimizes space usage in production facilities. The labelling system is also equipped with sensor-based controls for accurate label application, reducing the risk of misalignment, and ensuring professional, high-quality presentation. Additionally, the machine’s easy-to-clean design supports hygienic standards essential for food and beverage production.

Cluster Pack Sleeve Wrapping Machine

The latest wrap around sleeve packaging machine by ELITER Packaging Machinery is the “CLUSTER-WRAP” C-30S Sleeving Machine that is designed for specifically cluster-packs.

“Cluster-Wrap” C-30S is capable to accommodate cluster-pack packaging format and wraps cardboard sleeve around primary packaging containers including cans, bottles, cups, jars, or so in arrangements as below:

• 2x2x1
• 2x3x1
• 2x4x1
• Or more side-packs depending on the container sizes.