Barreled water production line-5 Gallons-450BPH

Production process：

(1) Recycle barrel → (2) Remove the used cap → (3)Brush cleaning, pure water cleaning barrel → (4) Automatically put the barrel into the filling machine→ (5) Rinse with disinfectant, circulating water and purified water → (6) filling  and capping → (7)Manual light inspection → (8) Label on bottle mouth → (9) Date printing → (10) Palletizing → (11) Finished product warehousing

Workshop layout：

1.1  product introduction

5 gallon automatic filling machine is a full-automatic filling production line which introduces the production technology and process of foreign companies, integrates the advantages of similar products in Italy, France and other countries, and combines with the specific national conditions of our country through technical improvement. It is one of the most advanced water filling equipment in the world.

This equipment has advanced technology, reliable performance, scientific process, good food hygiene conditions, high degree of production automation and simple operation. It is an ideal filling equipment for companies and manufacturers, and is welcomed by the drinking water industry.

The machine body is made of high-quality stainless steel, and other parts are made of non-toxic, sanitary and durable materials. The electrical and pneumatic systems are made of foreign famous brand components, such as Mitsubishi PLC inverter, Mitsubishi touch screen, Omron sensor, France te contactor, German FESTO, Taiwan AIRTAC cylinder and control valve, etc.

1.2 main technical parameters

1.3 Equipment introduction

1.31  Remove cap machine

All of them are made of stainless steel 304, and other parts are made of non-toxic and durable series materials. The electrical and pneumatic systems are made of imported components. The structure is compact and consists of four parts: frame, cover pulling device, cover blowing device and conveying chain. Compared with the common decapitation head, there is no direct wear. The rotary part is equipped with an imported flange sleeve, so the adjustment is very simple. There is no pressure on the barrel in the decapitation process, and there is little wear on the bottle bottom and chain plate. PLC control, can control alone or on-line production.

1.32  Barrel brushing machine

The washing machine outside the barrel is a bottle washing process designed and created by our factory. For the barrel and brush contact and relative movement to achieve the effect of washing. It can wash the bottle neck, bottle body, bottle bottom and other parts. The bottle can complete the revolution around the main shaft and its own rotation in the machine, realizing all-round brushing, continuous bottle feeding and bottle discharging, and can be arranged online to implement flow operation. In view of the passive rotation of three groups of guide wheels, small rotation range and unsatisfactory external brushing effect of the original machine, the three groups of guide wheels are changed into four groups of cylindrical brushes which can rotate actively. The cylindrical brushes not only play the role of dividing barrels, but also complete the external brushing of barrels together with the central brush, so as to ensure better external brushing effect; In order to ensure the washing effect of the bottom of the barrel, the number of bottom brushes was increased from three groups to four groups; In order to prevent bottle sticking during bottle feeding, a star wheel device is added at the bottle feeding position to completely eliminate the possibility of bottle sticking. It can ensure that the bucket is clean after pre washing.

1.33  Washing /filling /capping machine

(1)  track of main conveyor chain of bucket washing: adopt 304 stainless steel chain of high quality standard. The chain is equipped with polytetrafluoroethylene cushion strip, which has small wear, small water channeling, convenient installation speed and long service life. The transmission power adopts the structure of air driven ratchet. The cylinder moves back and forth, the chain of washing can drives the five gallon bucket to go to a station, accurate and stable. The washing bucket conveyor chain plate is laser cut, with high strength. Five gallon barrels are positioned accurately.

(2)  the barrel washing mode shall be in accordance with the requirements provided by the demander. The main chain cylinder shall be designed reasonably, with stable lifting, coordination and convenient maintenance and adjustment. The internal washing is pressure internal flushing, and the spray washing is even, and the inner wall of the barrel is spray washed with pressure water. The water pressure at each nozzle is above 0.25MPa; One for each process of external spray washing. Pressure gauge is installed on the flushing pipe, and the flushing pressure is observed.

(3) circulating water tank: movable type, which can be moved out of each water tank separately for cleaning; And equipped with visual liquid level pipe, low level protection detection; All water tanks must be concave bottom and equipped with blowdown valve, which is convenient for drainage; Each water tank is equipped with a liquid adding bucket, and a double-layer (400 mesh on the first layer and 100 mesh on the second layer) screen, which can be cleaned or replaced during operation; The filter screen not only filters circulating water, but also filters the added liquid; Each water tank has manual stainless steel supplementary water inlet system; The bottle flushing water pipe adopts detachable structure.

 (4) alkali liquid water tank and medicine washing water tank: adopt 2.5mm thick 304L stainless steel. Alkali water tank is equipped with electric heater, and the heat preservation cotton is used to ensure that the heating temperature can reach 80 ℃, and equipped with temperature control device, which can directly adjust and display the temperature of heating water tank (equipped with metal thermometer); Bucket type air extraction device and air extraction 90 are set at the top of alkali washing machine and sterilizer º Stainless steel elbow, and draw out water vapor, and ensure normal air flow direction in equipment; The position and diameter of the air outlet are suitable to ensure the extraction effect of hot alkali steam and disinfectant odor（ Note: consider local temperature and design enough heating elements). According to the flow data and process requirements used by the demander, the volume of alkaline solution and disinfection solution water tank is designed, which is more conducive to saving energy and drug water consumption and reducing operation and management costs.

(6)  flushing water pump: adopt German wille pump. Each flushing pump is equipped with air control reversing three-way valve, which automatically controls the barrel washing time to ensure that the pump does not start frequently and does not cause the pump to generate high pressure with zero flow, thus improving the service conditions of the pump and improving the service life of the pump. Butterfly valve is installed between the water tank and the circulating water tank for maintenance;

4.6. inside the bucket washer: lighting tubes are provided at the side of each bucket washing process to observe the effect of barrel washing; And equipped with a blow device, blow off the bottom of the five gallon bucket water, reduce water channeling. In addition, each process is equipped with double layer transparent water curtain to solve the water channeling problem.

(7)  barrel washing process: 6 stations (can be designed as required by the demander): 1 → 2 hot alkaline water cleaning at 45 ℃ -65 ℃, 3 → 4 disinfectants, 5 → 6 clean water and external spraying.

(8)  filling machine, barrel washing out mode: horizontal out of barrel. When leaving the barrel, the washed bucket falls horizontally on the bucket turning frame, then turns it into a vertical position, and then pushes the bucket out to ensure that no water drops drop into the bottle during the bottle pushing process. The bucket washing machine is equipped with ultraviolet sterilization lamp tube at the bucket dropping place to further ensure the sterile environment of the empty bucket.

(9)  filling valve structure: the filling valve is independently designed by our company, which is made of 304L material and processed by stainless steel precision casting parts without dead angle mirror treatment. It is provided with a sealing ring and guide ring to avoid friction between metals, and it is stable and reliable. The filling method of cylinder track, the filling valve is accurate, reliable and does not act in error. The mechanism adopts mechanical control, low maintenance cost, convenient and stable operation. It is convenient, simple and quick to replace each seal.

(10)  filling principle: secondary filling is adopted. The filling valve is a new filling valve. During the filling process, when the detection switch detects a bucket, the flap cylinder moves upward, and at the same time, the pneumatic valve is injected, and the filling cylinder moves downward, and the filling valve is opened to start filling; When the filling time signal is input to PLC, the filling water inlet valve is closed, and the small flow continues to fill for two seconds. After filling, the filling cylinder moves upward and the filling valve will automatically close; The chain then starts and the five gallon bucket is sent from the conveyor chain to the cover.

(11)  filling parameters: filling utilization rate ≥ 95%, cap loss ≤ 1%, filling capacity up to standard (within the specified range) plus and minus difference of 5mm, and no obvious difference in liquid level.

(12)  cover straightening device: it is equipped with a storage cover box and a rotary lid straightener.

(13)  gland mode: cylinder type gland is adopted. Ensure the sealing of the cover;

Field operation: the filling machine is equipped with a field operation panel to realize local control, display the working status of the filling line, and have the function of manual control alone; When there is a fault, it can display the fault (such as motor, liquid level, etc.) and the cause of the fault, and have sound and light alarm. Meanwhile, the system can selectively turn off according to the alarm degree to maximize the protection of equipment safety.

1.34  Sleeve Labeling machine

The five gallon labeling machine is suitable for large-scale pure water product bottle mouth labeling and related product bottle mouth labeling machine. The equipment is simple to operate, accurate labeling position, and can highlight the perfect bottle shape of the bottle after shrinkage. It can form a complete production line with the front-end filling machine, with flexible selection of multi bottle type; It can cover round bottle, square bottle, oval bottle, special-shaped bottle, bottle mouth and bottle body.

The equipment has low cost and high efficiency. The speed of the machine can reach 2000 BPH (speed adjustable). The main machine can be adjusted up and down, and can be used for barreled water bottles with different heights