For beverage producers scaling their operations, a mid-capacity carbonated drink line is a strategic investment. A line rated for 3000-4000 bottles per hour (BPH) for a 450ml PET bottle offers the ideal balance of output and flexibility for growing brands. This guide breaks down the core components, technical specs, and process flow of such a system, using clear, professional terminology.
Core System Components & Technical Specifications
A complete line is an integrated system. Here are its key modules:
1. Blow Molding & Air Compression Unit: This section creates the bottles. It typically includes a fully automatic blow molding machine, molds for specific bottle sizes (e.g., 450ml), an auto loader, and a critical component: a screw booster integrated air compressor that provides the necessary high-pressure air for forming bottles
2. Bottle Conveying System: Efficiency is key here. An overhead air conveyor system gently transports bottles via their necks. A standard system can handle speeds up to 12,000 BPH with high efficiency (≥97%). Control is managed by sensor-based accumulation; when bottles back up to a set point, a clamping mechanism activates to manage flow
3. The Filling Line Heart: Rinsing, Filling, Capping Monobloc.This is the core where the product meets the package. The line is designed for a rated output of 3000-4000 BPH at 450ml
Process: Bottles are inverted and rinsed, then filled using isobaric (counter-pressure) technology** essential for carbonated drinks to preserve fizz and minimize foam. Filling occurs at a cold temperature, typically 0-5°C. Finally, caps are applied and torqued securely.
4. Carbonation & Mixing System (The Brix Blender):
This unit is critical for product quality. It precisely blends water, syrup, and CO₂. A well-designed system ensures a high CO₂ content, often reaching 3.5 volumes or more. The pressure within the carbonator is adjustable, allowing operators to create the optimal conditions for a stable and efficient fill. All parts contacting the beverage are made of high-grade stainless steel for hygiene.
5. Supporting Modules:
Warm Tunnel: Post-filling, bottles pass through a warm tunnel. This brings the bottle temperature closer to ambient to prevent condensation ("sweating") on labels. A typical unit for this line size might have an effective spray length of about 7.0 meters
Control & Automation: The system uses programmable logic controllers (PLCs) and sensors (e.g., photoelectric switches) for automated operation and monitoring. Key pneumatic components like cylinders and solenoid valves are often premium brands (e.g., SMC) for reliability.
A 4000 BPH PET carbonated beverage line is a sophisticated, integrated production solution. Success depends on precise engineering—from blow molding and gentle conveying to isobaric filling and exact carbonation. For brands ready to scale, partnering with a reputable manufacturer to detail specifications for bottle type, product characteristics (like pH ≥4.6), and factory layout is the essential first step toward a seamless installation and efficient production.