HOT JUICE PRODUCTION LINE
Complete Turn-key Thermal Filling Solutions from A to Z. Engineered by Fillron to Lock in Fresh Flavor, Ensure 100% Biological Safety, and Optimize Thermal Energy Efficiency.
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Complete hot juice production solutions from processing to filling and packaging.
Who It Is For
NFC / Pulp Juice
Pain Points/Needs
- The fruit pulp tends to settle and separate
- The juice is highly susceptible to oxidation and discoloration
- It is extremely sensitive to sterilization temperatures
Fillron Solution
Equipped with a high-pressure homogenizer and a vacuum deaerator, and combined with UHT flash sterilization, the process ensures stable pulp suspension while preserving the original fruit flavor.
Tea / Plant Protein
Pain Points/Needs
- The tea infusion tends to become cloudy upon prolonged standing (tea cream)
- High-temperature sterilization is required to prevent spoilage
Fillron Solution
A process combining pasteurization and hot filling is employed, supplemented by inverted-bottle sterilization and a multi-stage cooling tunnel, to prevent bottle deformation and thoroughly eliminate bacteria on the inner surface of the cap.
Medium & Large Brand
Pain Points/Needs
- High production capacity requirements (10,000–30,000 BPH)
- Need to reduce energy consumption
- Requirement for an extremely low defect rate
Fillron Solution
Offers an integrated system directly linking heat-resistant PET bottle blow molding with hot filling, equipped with a heat recovery and cooling system to achieve efficient, low-consumption, large-scale production.
Capacity & Scope
Suitable materials
Scope and Technical Parameters: Fruit juice, fruit tea, beverages containing fruit pulp, plant-based protein beverages
Description/Advantages: Compatible with handling high-viscosity materials and those containing fruit pulp (options include wide-flow-path pumps and anti-clogging valves).
Compatible bottle types
Scope and Technical Parameters: Heat-resistant PET Bottles
Description/Advantages: Heat-resistant preforms requiring special crystallization treatment are used, capable of withstanding high-temperature filling at 85°C–92°C.
Full-line production capacity
Scope and Technical Parameters:1,000 BPH - 24,000+ BPH
Description/Advantages: The blending, filling, and cooling sections are perfectly matched, ensuring no bottlenecks.
Filling temperature
Scope and Technical Parameters: 85°C – 92°C (High-precision constant temperature)
Description/Advantages: Ensure commercial sterility standards are met while avoiding nutrient loss due to overheating.
Filling accuracy
Scope and Technical Parameters: ±1 g / bottle (servo-controlled)
Description/Advantages: Precise filling accuracy helps reduce material loss, improve production efficiency, and guarantee every bottle meets quality standards.
Compliance Standards
Scope and Technical Parameters: GB/T 31121 / FDA / GMP
Description/Advantages: Features a sanitary design throughout the entire system, provides comprehensive 3Q validation documentation, and assists in obtaining SC certification.
Line Process Flowchart
Blending & Pasteurization Unit
Raw materials are mixed, vacuum degassed, and homogenized under high pressure. They are then heated to 85-92°C by a UHT/pasteurizer before entering an insulated/buffer tank.
Automatic PET Bottle Blowing Machine
Heat-resistant PET preforms are blow-formed and seamlessly transported to the hot filling machine via an air conveyor.
Hot Filling & Recirculation Monobloc
In a clean environment, hot water rinsing, high-temperature filling, and capping are completed. The material is automatically circulated back to maintain a constant temperature.
Bottle Tilting & Cooling Tunnel
The bottle is inverted to use the residual heat to sterilize the inside of the cap; then it passes through multiple spray cooling tunnels to quickly cool the contents of the bottle to below 40°C, preventing the bottle from deforming.
Post-Packaging Network
A powerful air knife dries the bottle, followed by automatic labeling/sleeving, laser coding, film wrapping/carton packaging, and robotic palletizing and warehousing.
THE COMPLETE WORKFLOW BLUEPRINT
From Blending & Pasteurization to Final Sealed Cases. Explore Our Specialized Recirculation Loop Designed to Prevent Temperature Drops and Bottlenecks.
01
Water Treatment System
01
Water Treatment System
Multi-media filtering, activated carbon adsorption, and advanced Reverse Osmosis (RO) membranes to transform raw water into crystal-clear mineral or pure water conforming to global standards.
02
Blending & Pasteurization Unit
02
Blending & Pasteurization Unit
High-precision syrup blending tanks integrated with UHT (Ultra-High Temperature) plate/tubular pasteurizers to eliminate pathogens while preserving juice nutrition.
03
Automatic PET Bottle Blowing Machine
03
Automatic PET Bottle Blowing Machine
Specialized heat-set blowing technology producing crystallized bottle necks and ribs to withstand hot vacuum stresses.
04
Bottle Inversing & Cooling Tunnel
04
Bottle Inversing & Cooling Tunnel
Tilts the bottle to sterilize the cap interior with hot juice, followed by multi-stage water spraying to rapidly bring juice down to ambient temperature.
05
Post-Packaging System
05
Post-Packaging System
High-speed shrink sleeve labeling, laser code printing, automatic wrap-around carton packing, and robotic palletizing.
Plant & Utility Requirements
Factory Space and Cleanliness
- Space: Space must be reserved for the bottle-inverting machine and the long-distance cooling tunnel.
- Cleanliness: The hot-filling room must meet Class 10,000 cleanliness standards and be equipped with air purification and positive pressure systems.
Steam Requirements
- Core requirements: For UHT sterilization, sugar dissolving, and CIP cleaning.
- It is recommended to use a stable steam boiler with a pressure of 0.6–0.8 MPa.
Cooling Water System
- Core requirement: The cooling tunnel consumes a large amount of water.
- It is recommended to equip the unit with a cooling tower and a chiller to achieve the recycling of cooling water and significantly reduce operating costs.
Compressed Air and Electricity
- Power supply: 380V / 50Hz / 3-phase
- Compressed air: A refrigerated dryer is required to ensure the air supply for pneumatic components and bottle blowing is free of water and oil.
Configuration & Options
| Standard Economy | Standard Economy | Standard Economy |
| 1,000 - 4,000 BPH | 5,000 - 18,000 BPH | 19,000 - 24,000+ BPH |
| Semi-automatic blending + basic hot-filling machine; simple spray cooling tunnel; basic PLC control. | Fully automatic blending and sterilization + hot-fill/recirculation integrated machine; inverted-bottle sterilization + multi-stage cooling tunnel; automatic downstream packaging. | Servo direct-drive hot filling machine; AI-based full visual inspection; heat recovery cooling system; MES system integration. |
| Suitable for: Juice startups and contract manufacturers. | Suitable for: Medium-to-large juice and tea beverage brands. | Suitable for: Leading beverage companies, premium NFC (Not From Concentrate) juices. |
Turnkey Project Steps
01
Formulation Analysis and Process Validation
Based on the pH value and pulp content of the fruit juice/tea beverage, determine the sterilization temperature, time, and filling process.
02
Overall Production Line Layout Design
Key planning areas include the length of the cooling tunnel, workshop drainage, and the routing of steam piping.
03
Equipment Manufacturing and FAT Acceptance
Hot water testing is conducted at the factory to verify the stability of the temperature control and recirculation systems.
04
On-site Installation and SAT Commissioning
Engineers provide on-site installation, assist with commercial sterility testing, and facilitate the passing of SC certification audits.
05
Training and Lifelong After-Sales Service
Provides training on hot-filling process parameter adjustments; offers 24-hour remote response and lifetime technical support.
Customize Your Production Line
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FAQ
Why must "heat-resistant PET bottles" be used for hot-filled juice?
Standard PET bottles undergo severe shrinkage and deformation during high-temperature filling above 85°C. Heat-resistant PET preforms undergo a special crystallization process prior to blow molding, enabling them to withstand high hot-filling temperatures without compromising the bottle's shape. Fillron ’s blow molding machines allow for the optimization of heating profiles specifically for heat-resistant preforms.
Will the fruit juice inside the piping spoil when the hot-filling machine is shut down?
No, it will not. Fillron’s integrated hot-filling machine is equipped with an automatic recirculation system. If the filling machine stops for any reason or the downstream packaging line becomes blocked, the high-temperature product is automatically diverted back to the sterilizer or buffer tank to circulate and maintain heat; this ensures the product remains above the sterilization temperature at all times, thereby eliminating the risk of spoilage.
Why are "bottle inversion" and "cooling tunnels" still required after hot filling?
This is the core of the hot-filling process. Bottle inversion utilizes the high-temperature product (above 85°C) to sterilize the inner surface of the cap, ensuring commercial sterility; the cooling tunnel rapidly lowers the product temperature to below 40°C, halting thermal reactions to preserve flavor while preventing heat-resistant PET bottles from deforming due to prolonged exposure to heat.
Does the cooling tunnel consume a large amount of water? How can costs be controlled?
Traditional cooling tunnels do indeed consume significant amounts of water. Fillron offers heat recovery and cooling water recycling systems; through a closed-loop design incorporating cooling towers and chillers, cooling water can be recirculated, drastically reducing water utility bills and wastewater treatment costs.
My fruit juice contains large pulp particles; will the equipment get clogged?
For juices containing pulp, we have equipped the blending unit with a high-pressure homogenizer to refine the pulp, and in the filling process, we have selected a large-flow-channel filling valve to prevent clogging and ensure that the pulp passes through smoothly without damaging the integrity of the fruit pieces.
What kind of after-sales and technical support services does Fillron provide?
We provide full lifecycle after-sales support: free on-site engineer guidance for installation and sterility testing; training for your operators on hot filling processes and equipment maintenance; 24/7 online technical support; and a comprehensive spare parts inventory to ensure that vulnerable parts are shipped within 48 hours.
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