5,500–36,000 bph

Blow-Fill-Cap Combiblock

The combiblock combines a blow molder, filler and capper into a single unit: the bottle moves from mold to fill valve in seconds, with no air conveyor or buffers.

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Product: Water, carbonated beverages, juices, tea
Container: PET, 0.25–2.0 L
Output: 5,500–30,000 bph depending on volume
Model range: KM-CGX06-18-06 … KM-CGX18-60-20
Blow cavities: 6–18
Fill valves: 18–60
Capping heads: 6–20
Space savings: 25–40 % versus a separate-unit layout

About the solution

A conventional layout requires an air conveyor, a buffer accumulator and synchronization of three separate machines. The combiblock removes these links: the bottle is transferred directly by a mechanical star wheel, cutting the line's footprint by 25–40 % and reducing the risk of container contamination.

The KM-CGX06-18-06 … KM-CGX18-60-20 model range covers 5,500 to 30,000 bph depending on container volume. Fewer stations mean fewer failure points, and lower electricity and compressed-air consumption per bottle.

Built into the design

No conveyor between stations

Bottle transfer by mechanical star wheels: a short, fully enclosed path from blowing to capping.

Smaller floor plan

Removing the air conveyor and accumulator frees up roughly a quarter of the line's footprint.

Single control system

One PLC and one HMI for three operations — simpler operation, fewer synchronization issues.

Energy savings

Fewer drives and less compressed air per bottle compared with a separate-unit layout.

Line composition along the product flow

8 positions along the product flow. Every unit opens in the catalog: series, specifications, scope of supply and a quote request.

Full equipment catalog

Line model selection

Selecting a combiblock for CSD at 30,000 btl/h

Model range for carbonated beverages, 0.5 L container. Full blowing, filling, and capping specifications are in the "Combiblock" section.

Model	Blow cavities	Filling valves	Capping heads	Output (0.5 L)
EDS-DCX 14-60-15	14	60	15	24,000 btl/h
EDS-DCX 16-80-15	16	80	15	27,000 btl/h
EDS-DCX 18-90-18	18	90	18	30,000 btl/h
EDS-DCX 20-108-20	20	108	20	36,000 btl/h

For 30,000 btl/h the base model is EDS-DCX 18-90-18. Adjacent models are shown for headroom and growth potential assessment.

Line composition and floor space

Approximate values for a "combiblock + auxiliary equipment" package at 30,000 btl/h.

Parameter	Value
Installed line power	≈170 kW
Filling area floor space	800–1,000 m²
Operators per shift	5–6
Floor space savings vs. separate scheme	25–40%

Floor space and power are refined after agreeing on the plant layout and auxiliary system scope.

Line process flow

At 30,000 btl/h the combiblock handles blowing, filling, and capping in a single unit — the line is shorter and needs no air conveyor. The "head" and "tail" of the CSD line include product carbonation and bottle warming before labeling; see the "Combiblock" section for the technology of the blow-fill-cap unit itself.

What the combiblock brings to a CSD line

One unit instead of three separate machines — a shorter bottle path, fewer transfer points, and less container breakage
25–40% floor space savings in the filling area from eliminating the air conveyor and buffer
A single PLC for blowing, filling, and capping — a 30,000 btl/h line is run by 5–6 operators
Isobaric filling of CO₂ beverages with no desynchronization between blowing and filling
Camera inspection of the preform neck and bottle backlight — defects removed before the product is added
Fast bottle format changeover without stopping to replace the air path

Full layout for the EDS-DCX 18-90-18 rate: from preform and syrup to the finished pallet.

1Preform feeding and orientation
2Mixer-carbonator
3Blow-fill-cap combiblock (isobaric)
4Cap feeding and rinsing
5Bottle backlight inspector (FBI)
6Bottle warmer (condensate removal)
7Bottle air-blow drying
8Labeling machine
9Date coding / batch marking
10Shrink film packing in PE
11Palletizer and stretch wrapper

Key line stations

What sits behind the nameplate output: contact-part execution, operating logic and service points for every station.

Blow molding machine

PET container production

IR oven with zoned heating: even material distribution across the bottle wall.
Two-stage blowing with air recovery — up to 30% savings in compressor power.
Mold changeover for a different volume — from 30 minutes with two operators.
Direct coupling to the filler or via an air conveyor, depending on the plant layout.

This station's equipment in the catalog

Core machines of the line

Equipment of the “Blow-Fill-Cap Combiblock” layout: each tile opens the catalog with series, specifications and a quote request for that machine.

Blow-fill-cap combiblock

A preform enters the machine and a sealed, filled bottle exits: blowing, filling, and capping are combined in a single frame without an air conveyor.

Cap feeding and rinsing

Hopper elevator, orienter, and cap rinser before each capping head, with cap-presence monitoring.

Bottle backlight inspector (FBI)

Camera inspection of the empty bottle before filling: foreign inclusions, neck deformation, and preform residue are rejected before the product is added.

Mixer-carbonator

Water deaeration, syrup dosing, and CO₂ saturation before feeding the combiblock's isobaric valve.

Bottle warmer

Removes condensate from the cold bottle before labeling and coding — self-adhesive labels and print adhere without peeling.

Bottle air-blow drying

Final blow-off before the labeler: remaining surface moisture is removed by an air stream.

Labeling machine

PVC shrink sleeve with tunnel or glue roll-fed label — matched to the CSD packaging design.

Date coder and batch marking

Continuous inkjet printing of fill date, shift, and batch number with code readability verification before packing.

Shrink film packer

Group packing of 2×3, 3×4, or 4×6 in PE film with a shrink tunnel at the output of the high-speed combiblock.

Palletizer and stretch wrapper

Layer-by-layer pallet formation at 30,000 btl/h and stretch film wrapping with pre-stretch at the line output.

Which closure do you use

The cap type defines the capping block: heads, feeding and orientation of the closure, torque or press-on force. State your option in the request and we will select the head and sorter for it.

PCO 1881 / 28 mm / 38 mm

Plastic screw cap

The tamper-evident band tears on opening. Torque is set on the HMI and monitored on every chuck.

Capping unit: Magnetic screwing head

PCO 1810 / 28 mm

Sport push-pull cap

Drinking water and isotonic drinks. The spout is fed oriented, torque 1.2–2.0 N·m, logged in the report.

Capping unit: Magnetic screwing head

Capping machines in the catalog Match a capper to my container

Auxiliary systems of the line

The engineering utilities without which a line never reaches its rated output: water and product preparation, sanitation, container handling.

Preform feeding and orientation

The combi-block inlet.

Hopper with an elevator and preform orienter, neck-up
Rejection of deformed and contaminated preforms
Accumulation buffer synchronized with oven output
Preform-presence check at every feed position

Oven and blow-molding station

The heart of the combi-block: the container is formed right here.

Infrared oven with zoned heating control along the preform height
Two-stage blow with high-pressure air recovery
Water-cooled, quick-change molds
Direct bottle handoff to filling — no air conveyor, no dust pickup

Filling and capping block

Three operations on one frame with a single drive.

Filling valves for gravity, isobaric or hot fill, matched to the product
Capping heads with a magnetic clutch and torque control
Neck-hang transfer of the container — the bottle body never touches surfaces
Format change by recipe entry and neck-grip replacement

Compressed air and pneumatics

40-bar blow air and process air for the automation.

Separate low-pressure process air and 40-bar blow-air circuits
Dryer, in-line filters and receiver, dew point set for food-contact requirements
Oil-free compressors for circuits contacting product and the container's inner surface
Stainless steel piping with take-off points and shut-off valves at every station

CIP station (clean-in-place)

Filling-loop wash without dismantling the block.

Alkali, acid and hot-water tanks holding temperature within ±2 °C
Recipe-driven wash programs: phase time, concentration and flow are logged
Flow meter on the supply line — actual flow is verified, not assumed from the nameplate
Filtered detergent return to the tanks; discharge only once the solution is spent

Conveying systems

Discharge of the capped bottle to labeling and packing.

Air conveyor for empty containers with air filtration and neck guide rails
Slat-top conveyor with independent drives and accumulation buffers between stations
AISI 304 frame, Siemens / Schneider drives and controls, Sick photo sensors
Photoelectric jam detection with automatic section stop before a line stoppage

FAQ

When is a combiblock more cost-effective than a separate-unit layout?

From about 8,000 bph and with limited floor space. At lower speeds a separate-unit layout is more flexible: stations can be added incrementally as you grow.

Can the bottle format be changed?

Yes, by replacing the molds and adjusting the recipe. A format change takes 1.5–3 hours depending on the geometry difference.

How much does the Blow-Fill-Cap Combiblock cost?

Price on request: the budget depends on output, container type, line composition and the level of automation. After a short brief we send a preliminary estimate within 1–2 working days and a full quotation broken down by machine within 3–5 days.

What are the delivery and commissioning lead times?

Standard machines ship 8–12 weeks after the specification is confirmed, complete lines 12–20 weeks. Transport takes 2–6 weeks depending on the route; installation and commissioning on site take 2–4 weeks, with operator training included.

What output does this line reach?

The working range is 5,500–36,000 bph. Exact output is confirmed against your container, product and shift plan: we calculate the line balance and keep a margin on the bottleneck machine.

Request a quote: Blow-Fill-Cap Combiblock

Tell us the product, the container and the target output — we will return the line composition, a layout, a budget range and a delivery schedule.

Services for this line

Engineering, logistics, installation and service that turn this line into a working production site.

Engineering services

Technical audit of the site and production facility

Our engineers visit the site and survey the workshop, utilities and logistics. We record site constraints before they turn into rework during installation.

Business plan and financial model for a bottling line

We calculate project payback before the contract is signed: scenarios for raw materials, currency, sales channels and line load. The output is a document you can take to a bank, an investor or the board.

Process line design

Technology, specification, layout, throughput and utility calculations. The document equipment is ordered against and installation is carried out with.

Site selection and construction works

We help choose a plot or existing building, connect utilities, prepare the master plan and manage construction — from groundbreaking to workshop handover.

Digital layer

Any line can be supplied with a digital layer

SCADA, MES, OEE monitoring, batch traceability and integration with plant systems — engineered together with the line, not bolted on later.

Production digitalization How we work: customer portal