Juice Filling Line, Glass
Glass for juice is a premium segment with a different set of stations: gentle container handling, twist-off capping and, where needed, tunnel pasteurisation of the already-closed bottle.
- Product
- Juices, nectars, compotes, iced tea
- Container
- Glass 0.2–1.0 L
- Output
- 1,500–12,000 bph
- Filling
- Hot gravity or vacuum
- Capping
- Twist-off, crown cap, screw cap
- Pasteurisation
- Tunnel type, up to 4 temperature zones
- Container washing
- Rinsing of new containers or alkaline washing of returnable ones
- Materials
- AISI 304 frame, AISI 316L product path
Line parameters
About the solution
A glass bottle is heavier and more fragile than PET, so conveyors are built with gradual acceleration and side guides, and starwheels are polymer to avoid scratching. Line speed is set with the container's allowable load in mind.
The product is filled hot (85–92 °C) and sealed with a twist-off cap, which forms a vacuum as it cools. For sensitive recipes a tunnel pasteuriser with stepped heating and cooling of the closed bottle is added.
Built into the design
Gentle handling
Gradual acceleration, polymer starwheels and adjustable guides keep glass breakage to a fraction of a percent.
Vacuum on cooling
Hot filling with a twist-off cap forms a vacuum, which serves as a pack-integrity indicator for the shopper.
Tunnel pasteurisation
Treatment of the already-closed bottle: guaranteed microbiological safety for preservative-free recipes.
Returnable glass capability
Optional bottle washer with an alkaline circuit and residual-label control.
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.
- 1
1. Depalletising and glass feed
Layer-by-layer pallet breakdown, feeding onto the conveyor with gradual acceleration.
Juice and pulp drink filling →
- 2
2. Washing or rinsing
Rinsing of new containers or a full alkaline wash of returnable glass.
Beer and low-alcohol drink filling →
- 3
3. Product pasteurisation
Tubular or plate pasteuriser with holding time and heat recovery.
Juice and pulp drink filling →
- 4
4. Hot filling
Gravity or vacuum filling at 85–92 °C with level control.
Juice and pulp drink filling →
- 5
5. Twist-off capping
Cap feeding, screwing with torque control, reject of under-torqued caps.
Capping equipment →
- 6
6. Tunnel pasteuriser
Stepped heating and cooling of the closed bottle (recipe-dependent).
Juice and pulp drink filling →
- 7
7. Labelling and date coding
Self-adhesive or glue label, back label, batch date coding.
Labelling equipment →
- 8
8. Case packing and palletising
Case erector, loading, sealing and palletising.
Packing and palletising →
Line model selection
Selecting a tri-block for juice filling into glass
Output is given for 0.25–2 L containers with hot filling in the rinse — fill — cap sequence.
| Model | Rinsers / valves / capping heads | Output | Fill accuracy |
|---|---|---|---|
| EDS-HW8-8-3 | 8 / 8 / 3 | 1,000–3,000 btl/h | ±1% |
| EDS-HW12-12-4 | 12 / 12 / 4 | 4,000–8,000 btl/h | ±1% |
| EDS-HW18-18-6 | 18 / 18 / 6 | 8,000–15,000 btl/h | ±1% |
| EDS-HW24-24-8 | 24 / 24 / 8 | 15,000–24,000 btl/h | ±1% |
| EDS-HW32-32-10 | 32 / 32 / 10 | 24,000–32,000 btl/h | ±1% |
Container range 0.25–2 L, heat-resistant glass. Contact parts and the product tank — AISI 304/316, key electrical components by Mitsubishi, OMRON, Siemens.
Auxiliary systems
The line composition upstream and downstream of the tri-block depends on the raw material and shelf-life requirements.
| Unit | Purpose |
|---|---|
| Water treatment station | Clarification, softening, reverse osmosis, UV disinfection of process water |
| Bottle inverter | Sterilization of the cap and headspace using the product's own heat after capping |
| Cooling tunnel | Multi-zone showering with decreasing temperature, prevents thermal shock to the glass |
| Cold-glue labeling machine | Die-cut paper or foil label on cylindrical and shaped containers |
| Case packer | Loading bottles into a corrugated case with interlock when no container is present |
Line process flow
The glass juice filling line is built around a hot-fill tri-block: juice, tea, and other heat-resistant beverages are filled at pasteurization temperature, and the capped bottle passes through inversion and cooling before labeling.
Key line features
- 3-in-1 rinse — fill — cap technology, PLC control with a touchscreen panel
- Changing a few parts allows switching to tea, dairy, and energy drinks
- Output 1,000–32,000 btl/h, containers 0.25–2 L
- Contact parts and the product tank — AISI 304/316, polished with no dead zones
- Magnetic capping heads: no bottle — no cap, rejection rate ≤0.2%
- Key electrical components by Mitsubishi, OMRON, Siemens
- Fill accuracy within ±1%
Full cycle from product preparation to the pallet for direct-press or concentrate-based juice.
- 1Water treatment station
- 2Juice cooking/blending block and pasteurization
- 3Glass bottle unscrambler
- 4Rinse — hot fill — cap tri-block
- 5Bottle inverter (cap sterilization)
- 6Cooling tunnel with multi-zone showering
- 7Cold-glue labeling machine
- 8Date coder / batch marking
- 9Case packing and palletizing
Key line stations
What sits behind the nameplate output: contact-part execution, operating logic and service points for every station.
Blending and UHT block
Product preparation
- High-shear blending unit: sugar, concentrate and stabilizer disperse without clumping.
- Tubular or plate heat exchanger, holding and cooling on a set curve.
- Homogenizer up to 200 bar — a stable emulsion with no separation in the bottle.
- Jacketed buffer tank maintains the filling-supply temperature.
Core machines of the line
Equipment of the “Juice Filling Line, Glass” layout: each tile opens the catalog with series, specifications and a quote request for that machine.
Water treatment station
Mechanical filtration, softening, carbon filtration, reverse osmosis, and UV disinfection of process water for the blending room.
Juice cooking and blending block
Concentrate dissolving or direct-press juice, pasteurization, and deaeration of the product before hot filling.
Glass bottle unscrambler
Depalletizing and orienting glass containers before feeding to the rinser, with starwheels that avoid direct contact with the neck.
Rinse — fill — cap tri-block
Rotary monoblock for heat-resistant glass containers: nozzle rinsing, volumetric hot filling by level, and magnetic capping.
Bottle inverter
Turns the bottle over after capping to sterilize the cap and headspace using the product's own heat.
Cooling tunnel
Multi-zone showering with decreasing temperature brings the bottle back to room temperature without thermal shock to the glass.
Cold-glue labeling machine
Rotary application of die-cut paper labels on cylindrical or shaped glass bottles, speeds up to 72,000 btl/h.
Date coder and batch marking
Inkjet printing of the fill date and batch number on the bottle and case with code readability checking.
Case packer
PLC-controlled bottle positioning and lowering into the case, with drive interlock when a container is missing.
Palletizer and wrapper
Layer-by-layer pallet formation from cases and stretch-wrap with pre-tension before shipment to the warehouse.
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.
TO-53 … TO-82
Metal twist-off lid
For jars with sauces, jams and preserves. Works together with vacuum or steam injection before capping.
Capping unit: Seaming/screwing head
28×18, 30×60 (ROPP)
Aluminum screw cap
The thread is rolled directly onto the bottle neck, the skirt is crimped over the finish — tamper-evidence without an extra seal.
Capping unit: ROPP thread-rolling head
26 mm, 21 teeth
Crown cork
Beer, soda, cider. Crimping over the finish with force control — seal integrity up to 4 bar in-bottle pressure.
Capping unit: Crown head with magnetic chuck
PVC, PET, polylam
Heat-shrink/polylaminate capsule
Decorative finishing over the closure: capsule placement, crimping over the finish, hot-air shrinking.
Capping unit: Capsule dispenser + heat tunnel or roller crimping
Auxiliary systems of the line
The engineering utilities without which a line never reaches its rated output: water and product preparation, sanitation, container handling.
Water treatment
Water for reconstitution, rinsing and pasteurization.
- The scheme is built from a feed-water analysis: mechanical filtration, carbon, softening, reverse osmosis
- Station output sized with a 20% margin over peak line consumption and wash cycles
- Membranes with automatic flushing and VFD-driven pumps — no water hammer
- UV and ozone disinfection, AISI 316 buffer tank with a breather filter
Depalletizing and glass washing
The line's inlet for glass bottles.
- Depalletizer removing layer sheets and feeding the slat conveyor
- Rinser with filtered water and sterile-air drying
- Chip and finish-crack inspection before the filler
- Smooth star-wheel guides — minimal chipping and noise
Blending and pasteurization block
Product preparation for hot filling.
- Concentrate reconstitution, deaeration and homogenization up to 200 bar
- Tubular pasteurizer with heat recovery and a 15–30 s hold
- Filling at 85–92 °C with product recirculation through the filler carousel
- Brix and pH control per batch, logged
Glass-bottle cooling tunnel
Glass is sensitive to temperature swings.
- Stepped showering with no more than 20 °C between zones
- Zone-by-zone temperature control, thermal-shock breakage protection
- Water recirculation with filtration and disinfection
- Air blow and drying before labeling
CIP station (clean-in-place)
Wash of the blending and product loops.
- 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
Coding and inspection
Date and batch on the label or on the cap.
- Inkjet or laser coder: date, shift, batch number, traceability code
- Fill-level, cap presence and seating inspection with automatic reject to a pocket
- Good/reject product counters logged per shift hour
- Ready for mandatory marking: case and pallet aggregation at the line outfeed
Packing and palletizing
Corrugated case packing and glass-container palletizing.
- Shrink film pack or corrugated case, format tailored to the retailer's requirements
- Layer palletizer to a defined pattern, robotic version for constrained floor space
- Pallet wrapper with pre-stretch film: lower film consumption, pallet withstands transport
- SSCC pallet label printing and application, data handoff to the ERP system
FAQ
Is tunnel pasteurisation needed on top of hot filling?
Not always. For juices with pH below 4.2, hot filling alone is usually sufficient. For less acidic recipes, a tunnel pasteuriser is mandatory.
What glass breakage rate is considered normal?
On a well-tuned line, 0.1–0.3%. Higher breakage almost always points to incorrectly set guides or an unsuitable container geometry.
How much does the Juice Filling Line, Glass 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 1,500–12,000 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: Juice Filling Line, Glass
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.
Related solutions
Lines with a similar equipment set — useful when you plan several products on one site.
2,000–18,000 bph
Hot-Fill Juice Line, PET
Pasteurisation, filling at 85–92 °C, cooling tunnel and labelling.
Open solution2,000–12,000 bph
Hot-Fill Juice-with-Pulp Line, PET
Large-bore valves and piston dosers for drinks containing particulates.
Open solution1,500–8,000 bph
Juice-with-Pulp Filling Line, Glass
Piston dosing of product with particulates into glass with hot filling and pasteurisation.
Open solutionServices for this line
Engineering, logistics, installation and service that turn this line into a working production site.
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.