CAPACITY: 600BPH 5 GALLON BOTTLING LINE PROPOSAL …timmex-bg.com/.../08/Proposal_of_600BPH_5_Gallon_Bottling_Line_10 … · CAPACITY: 600BPH 5 GALLON BOTTLING LINE ... Proposal for

PROPOSAL OF BOTTLING PLANT

CAPACITY: 600BPH 5 GALLON BOTTLING LINE

PROPOSAL NUMBER：PW-2012V600B3011

Proposal for 600BPH 5 Gallon Bottle Filling Line --------------------------------------------------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------------------------------------------------

Page 2 of 32

TABLE OF CONTENTS

1. PRICE LIST AND BUSINESS TERM....................................................................... 3

1.1 Price List (F.O.B Shenzhen Port) .................................................................. 3 1.2 General Business Term .................................................................................. 3 1.3 Special Statement............................................................................................ 3

2. GENERAL DESCRIPTION OF THIS PROPOSAL................................................... 4

2.1 Capacity............................................................................................................. 4 2.2 Decapper ........................................................................................................... 4 2.3 Outer Washer ................................................................................................... 4 2.4 Inner Washer .................................................................................................... 5 2.5 Filler ................................................................................................................... 7 2.6 Cap Feeder and Cap Washer ........................................................................ 7 2.7 Pump Station/Water Supply Station (Optional)........................................... 8

3. DETAIL PROPOSAL OF 5 GALLON BOTTLING LINE ........................................ 10

3.1 Price Breakdown ........................................................................................... 10 3.2 Options’ Price and Details ........................................................................... 11

4. RINSING STAGES OF INNER WASHER .............................................................. 12

5. SAMPLE LAYOUT OF 5 GALLON BOTTLING LINE............................................ 13

6. WASHING STAGES DESCRIPTION AND WASHING TIME ................................. 14

7. COMPONENTS AND HIGHLIGHTS ...................................................................... 17

8. PHOTOS OF LINEAR 5 GALLON BOTTLING LINE ............................................. 19

8.1 Decapper ......................................................................................................... 19 8.2 Linear Outer Washer ..................................................................................... 20 8.3 14-Stages Inner Washer ............................................................................... 22 8.4 Rinsing Nozzle ............................................................................................... 23 8.5 Filler ................................................................................................................. 26 8.6 Cap Washer .................................................................................................... 27 8.7 Cap Feeder ..................................................................................................... 28 8.8 Optional Automatic Chemical Dosing System........................................... 28 8.9 Food-Grade Chemical Tanks with Manhole .............................................. 29 8.10 Air Filter ........................................................................................................... 30 8.11 Water Supply Station..................................................................................... 31


--------------------------------------------------------------------------------------------------------------------------------

Page 3 of 32

1. PRICE LIST AND BUSINESS TERM

1.1 Price List (F.O.B Shenzhen Port)

Item Price (EUR)

Explanation

600BPH 5 gallon bottling line

109312.00

Please refer to below detail.

Installation material

4615.00

Including welding machine, welding kits, wire and cable within bottling line, piping system within bottling line, tools, etc

Packing cost

1950.00

By wooden box. 30.00EUR per cubic as per Non-ISPM15 standard. Total 65 cubes.

Installing subsidy

1800.00

60.00EUR per person per day. Project needs 2 persons, 15 days.

Land transportation charge

300.00

Total

117977.00

1.2 General Business Term

1.2.1 Payment: 45% down payment, 55% before delivery.

1.2.2 Delivery time: 90 days after down payment.

1.2.3 Flight and local accommodation cost of installing team is covered by

customer.

1.2.4 The proposal will be in valid before January 1st, 2015.

1.2.5 The proposal includes installation service, and training on operating this

machine. It includes one year guarantee, and life time maintain service.

1.3 Special Statement

1.3.1 The goods/service mentioned above is actually priced in Chinese

currency RMB, but paid by Euro for easily international banking


--------------------------------------------------------------------------------------------------------------------------------

Page 4 of 32

transfer. The total amount above is based on the fixed currency

exchange rate 1:8.10 between Euro and Chinese RMB. In case at the

time the buyer makes payment, the Chinese RMB has depreciation

compared with Euro. The buyer pays less accordingly, and vice

versa. The newest exchange rate is referred by www.xe.com .

1.3.2 What we quote is the complete fully automatic production line. However,

it is acceptable to us that you only purchase some of the machines on

the list.

2. GENERAL DESCRIPTION OF THIS PROPOSAL

2.1 Capacity

Capacity of 5 gallon bottling line is 600 BPH (bottle per hour)

2.2 Decapper

This proposal adopts single head decapper.

Bottle arrives at its right position, a cylinder stops it. Then decapping–head

unit goes down, clutching cap and pulling out it from bottle mouth. Cap is

collected by a side sucker.

2.3 Outer Washer

By using linear outer washer to clean the bottle surface.

It consists of two parts: detergent liquid rinsing section, and resued water

rinsing section.

This outer washer firstly rinse bottle with heated alkali detergent liquid.

Bottle is driven forwards by belt pulling. While bottle is forwards reelingly,

hot heated alkali and brushes clean every inch of the bottle surface. The

http://www.xe.com/


--------------------------------------------------------------------------------------------------------------------------------

Page 5 of 32

rinsing time of each bottle reaches 9 seconds, which ensures bottle

surface is effectively cleaned.

After it, bottle enters reused water rinsing section. The reused water

spurts out from all kinds of direction. It thoroughly rinses the residual dirty

liquid on the bottle. As it adopt resued water from inner washer, so it can

reduce water consumption.

It is equipped with sensors. This outer washer works in self-adaptive

speed mode. If there is no bottle entering, it will stop working. When

bottles enter again, it works automatically. If there are too many bottles in

front of it, it will stop working. When the bottles move forwards, it works

again. It is automatical and reduces energy consumption.

It adopts linear design, which can effectively avoid bottle jam.

2.4 Inner Washer

2.4.1 To thoroughly clean/sterilize the re-used bottle, inner washer adopts 14

washing/rinsing/sterilizing stages, 4 rows arrangement. It will use detergent, disinfectant, reused water and product water rinsing to clean the bottle.

About the detergent rinsing.

By using warm detergent liquid (50-85 oC) rinsing, the inner washer

effectively removes oil, water scale and various peculiar smells in a short

period.

About the disinfection rinsing.

By using disinfection rinsing, it can kill bacteria, fungi, viruses, and other

microorganism quickly. The most common used disinfectant in 5 gallon

industry is food grade ClO2, with concentration 250ppm.


--------------------------------------------------------------------------------------------------------------------------------

Page 6 of 32

About the reused water rinsing and product water rinsing.

We use two stages product water rinsing to make sure the bottle is

thoroughly cleaned.

There are three tanks are used for the storage detergent, disinfectant and

collecting water purpose.

All the tanks have the water level sensor which gives alarm if liquid level is

low and the whole machine will stop if liquid level is over-low. (This sensor

can trigger an optional automatic water replenishing system)

Optional automatic chemical dosing system are available in this system ,

when the concentration of the chemical liquid is low, the chemical dosing

pump will replenish chemical automatically。

Net-type filter to prevent solid material from entering chemical liquid tank

2.4.2 The water distributing pipe on which rinsing nozzles are installed use quick interface clamp, so it is easy to be disassembled and cleaned.

2.4.3 Quick-flow chute designing, decreasing consumption of electricity and

operational cost.

2.4.4 Bottle mouth sterilizing device can disinfect the bottle mouth effectively.

2.4.5 Unique oblique water tray can guarantee there is no residual water on the tray.

2.4.6 There is an UV sterilizer inside the machine

2.4.7 Balanced elevating device of rinsing-nozzle rack is equipped.

2.4.8 T-tube on filling distributing horizontal tank, eliminating the possibility of

accumulation of sediment.

2.4.9 Multi T-tubes on main rinsing distributing pipe. All rinse nozzle are jointed with the water distributing pipe by meaning of pulling-welding, thoroughly avoiding dead angle which otherwise will accumulate solid material.


--------------------------------------------------------------------------------------------------------------------------------

Page 7 of 32

2.4.10 Failure indicating light can help to find the failure points quickly and easily.

2.4.11 Special rinsing nozzles are applied in different position to achieve

the best rinsing effect, ensuring hygiene of bottle, and saving consumption of water/chemical. Please go to Rinsing Nozzle for detail

2.5 Filler

This filler is originally designed specially for one-way PET bottle with less

weight and thin wall/bottom, now is applied in all our 5 gallon linear-type

filling line since it has advantage in many aspects.

Non-touch filling nozzle does not bring press to the fragile PET one-way

bottle.

Multi-pressure filling principle+ frequency inverter is adopted, which

increases the pressure slowly and gradually, avoiding the damage to the

thin bottle bottom which otherwise will be caused by sharp strike of water.

There is no overflow at all. Based on time that is adjustable separately,

filling nozzle is on/off by electromagnetic valve.

Filling tank is in “ ”shape, which avoid dead angle, at the same time,

the pressure at each filling nozzle is the same, by which the water filling

quantity is easily controlled.

All filling nozzle is connected with main distributing pipe by means of

pulling-welding, eliminating the possibility of accumulation of sediment.

Filling nozzle is made of stainless steel 316L.

2.6 Cap Feeder and Cap Washer


--------------------------------------------------------------------------------------------------------------------------------

Page 8 of 32

There is a cap feeder and a cap washer equipped in this proposal, by

using a belt type cap sending device, the caps can be sent to the cap

feeding pipe smoothly.

2.6.1 Cap is put into cap container manually, then it is sent to cap washer

automatically by air blow. The fan of the cap feeder is equipped a filter.

2.6.2 Coming from cap feeder, cap is sent to unscrambler on the top of cap

washer, where it is organized in order. Then cap goes into cap washer

through a chute. Rinsing nozzle sprays sterilizing liquid and product

water thoroughly to clean cap. Washing stage includes drinkable water,

sterilizing liquid, drip. Then cleaned cap goes to capper via another

chute.

2.6.3 Cap lack alarm device is used

2.7 Pump Station/Water Supply Station

Pump station consists of main structure frame, one filling pupm, one

rinsing pump (both Grundfos), inverter of filling pump, piping system, and

control panel.

It delivers product water from the terminal of water treatment system to the

filling line.

The filling pump is controlled by PLC. It matches with the filler, to achieve

constant pressure filling of high speed.

Water supply station consists of pump station, ozone generator, ozone

mixer, product water tank, and control box.

Ozone mixer adopts two mixing process: liquid-gas mixing, and liquid-

liquid mixing, makes the gas and water fully contacted and dissolved. The

mixing rate is over 90%, which is 40%~50% more than the ordinary ozone


--------------------------------------------------------------------------------------------------------------------------------

Page 9 of 32

mixer (ozone mixing tower and Venturi-type ozone mixing). This ozone

mixing system is equipped with a mixer, mixing pump, 316 stainless steel

piping, and pressure meter, with small occupancy, low energy

consumption, stable running.

The product water tank is made of stainless steel. It is equipped with a

stainless liquid displayer, universal direction rinsing device (it can jet the

product water to every corner of the tank evenly, it can effectively clean

the tank except the equipment stop using for a very long time), air filter,

manhole for cleaning, liquid level control switch and the entire line-linked.

It reaches food-grade hygienics level, and effectively avoids produce water

gets secondary polluted.

This whole system is controlled by centrol control system. It runs

automatical, and synchronizes with the filling line. The ozone mixing

system, filling pump and rinsing pump run automatically as per the filling

line. It is easy to operate, and reduce energy consumption.

3. DETAIL PROPOSAL OF 5 GALLON BOTTLING LINE

Project: 5 gallon bottling line Bottle size: 18.9 liter Bottling speed: 600 bottle per hour

3.1 Price Breakdown

Item Type Unit Price (EUR)

Quantity Amount (EUR)

Explanation

Decapper BG-1 2763.00 01 set 2763.00 Single head

Outer washer WX-L-3 10563.00 01 set 10563.00 Linear stype

Automatic bottle feeder

SP-4 2160.00 01 set 2160.00

Inner washer/filler/capper

PW-600-4-14 58606.00 01 set 58606.00 Output: 600BPH for 5 gallon Filling heads: 4 Washing stages:14(*) Pump: German WILO Capping method: belt Inserting rotary/linear washing nozzle

Automatic cap feeder SG-900 2752.00 01 set 2752.00

Cap washer XG-900 7429.00 01 set 7429.00

Cap film shrinker 3020.00 01 set 3020.00 Steam type, with separately boiler

Central control cabinet CC-900 3381.00 01set 3381.00

Conveyor with belt 449.00/m 21.00M 9429.00

Conveyor motor 897.00/set 6 sets 5382.00 HAITECH


--------------------------------------------------------------------------------------------------------------------------------

Page 11 of 32

Roller-conveyor 505.00/m 7 M 3535.00

Lighting box 146.00 2 sets 292.00

Total 109312.00

Note: Total amount of conveyor and conveyor motor varies depending on final layout. All specifications are subjected to update without notification in advance.

3.2 Options’ Price and Details

Item Unit Price (EUR)

Quantity Amount (EUR)

Explanation

Automatic chemical dosing system

2500.00

02 sets

5000.00 Including chemical concentration censor, automatic water replenish mechanism, piping unit, expansion module of PLC

FFU

3786.00

01 set

3786.00 High efficient air filtration unit. Blows clean air (100 degree) down to filling area.

Pump station

6880.00

01 set

6880.00 Including: one filling pump, one rinsing pump , one inverter (for filling pump), control panel, and piping system.

Water supply Station

18950.00

01 set

18950.00 Including : Pump station, ozone generator, ozone mixer, control system, and product water tank.


--------------------------------------------------------------------------------------------------------------------------------

Page 12 of 32

4. RINSING STAGES OF INNER WASHER


--------------------------------------------------------------------------------------------------------------------------------

Page 13 of 32

5. SAMPLE LAYOUT OF 5 GALLON BOTTLING LINE


--------------------------------------------------------------------------------------------------------------------------------

Page 14 of 32

6. WASHING STAGES DESCRIPTION AND WASHING TIME

Stage Number

Main Function Explanation Lasting Time

1 Drip Give time to water that attaches on the bottle outer surface, which happens on outer washing machine, avoiding the water contaminating detergent (alkali solution) and decreasing concentration of alkali.

Compressed air blow nozzle is attached, to clean the residual water on bottle bottom.

24 seconds

2 Re-used water rinsing. By using high pressure pump, it can effectively remove solid materials that attaches on the inner surface, to avoid the residuals come into the alkali tank.

The rinsing water comes from the re-used water tank, saving operational cost. Inserting-type rotary nozzle, no dead angle.

24 seconds

3 Detergent rinsing. To adopt alkali to rinse inner wall of bottle. It can effectively remove oil, water scale and various unpleasant smells.

●Inserting-type rotary nozzle, no dead angle . ●Quick-flow chute and isolating box designing, decreasing consumption of electricity and operational cost. ●Low-water level detector and alarm. ●Over low water level automatic stop function. ●Net-type filter is installed to prevent solid material go to water tank. ●With electricity heater inside which can be easily cleaned and replace. ●Tank is attached with heat-resistant material, avoiding heat loss.

24 seconds

4 Detergent rinsing The same as stage number 3, excepting it adopt plane-head rinsing nozzle which supplies liquid with higher pressure.

24 seconds


--------------------------------------------------------------------------------------------------------------------------------

Page 15 of 32

5 Detergent rinsing The same as stage number 3. 24 seconds

6 Drip It collects the residual detergent back to detergent tank, to avoid the loss of chemical liquid.

24 seconds

7 Re-used water rinsing It can effectively clean the residual alkali that attaches on the inner surface, to avoid the alkali to react with disinfectant at next stage and further avoid the extra-consumption of disinfectant.

The rinsing water comes from the re-used water tank, saving operational cost. Inserting-type rotary nozzle, no dead angle.

24 seconds

8 Disinfectant It can kill bacteria, fungi, viruses, and other microorganism quickly.

●Inserting-type rotary nozzle, no dead angle. ●Low-water level detector and alarm. ●Over low water level automatic stop function. ●Tank is made of 316SS. ● Bottle mouth sterilizing device is equipped. ●Net-type filter is installed to prevent solid material go to water tank.

24 seconds

9 Disinfectant ●The same as stage number 8, excepting it adopt plane-head rinsing nozzle which supplies liquid with higher pressure.

24 seconds

10 Disinfectant The same as stage number 8, except no bottle mouth sterilizing device.

24 seconds

11 Drip Give time to the disinfectant which attached on the inner wall of the bottle for the disinfecting purpose.

24 seconds

12 Product water rinsing ●Inserting-type rotary nozzle. ●The water, after it rinses the bottle, goes back to a re-used water tank. ●Tank is attached with low-water level alarm and over-low water level automatic stop. It also adopts a overflow outlet bottle mouth sterilizing device

24 seconds


--------------------------------------------------------------------------------------------------------------------------------

Page 16 of 32

13 Product water rinsing ●The same as stage number 12 excepting it adopt plane-head rinsing nozzle which supplies liquid with higher pressure, no bottle mouth sterilizing device.

24 seconds

14 Drip 24 seconds

Remarks: The 24 seconds lasting time includes 19.5 seconds effective rinsing time for each nozzle and 4.5 seconds for the bottles move from one rinsing stage to the next rinsing stage


--------------------------------------------------------------------------------------------------------------------------------

Page 17 of 32

7. COMPONENTS AND HIGHLIGHTS

Item Function Description Main Components Highlights

Decapper Bottle arrives at its right position, a cylinder stops it. Then decapping–heads unit goes down, clutching cap and pulling out it from bottle mouth. Cap is collected by a side sucker.

Cylinder: AIR TECH Proximity switch：BANNER

SUS 304 stainless steel Frame and support structure

Compatible for wider tolerance of bottle height Does not hurt bottle mouth Does not hurt cap

Outer washer Driven by the electricity motor and cylinder, bottle moves step by step from one washing position to another. With the brush that is made very fit to bottle’s shape, the body, neck and bottom of the bottle can be thoroughly cleaned. Alkali liquid and clean water are used to thoroughly wash the bottle outer surface.

Cylinder: AIR TECH Pump: Wilo Motor: HAITECH SUS 304 stainless steel Alkali tank/pipe: 316L stainless steel

Thoroughly clean outer surface. Cost-saving designing principle. Clean water comes from inner washing section. Self-adaptive speed. No bottle, not working.

Inner washer Bottle is inserted into bottle-mouth-cup, and then is turned upside down. Rinsing nozzle inserts into inner space of bottle to washing inside surface.

Cylinder: AIR TECH Pump: Wilo Motor: HAITECH PLC: SIEMENS Contactor:Schneider

Transducer：MITSUBISHI/LG

Rinsing nozzle: 316L SS Frame: SUS 304 SS

Low consumption of alkali and sterilizing solution Energy-saving alkali heating system Inserting rotary rinsing nozzle. No dead-angle washing effect. Compressed-air blow valve, no residual water on bottle outer bottom. Washing water is re-used.

Filler Multi-pressure filling principle, one set frequency revert is adopted to minimize the change of water pressure within the filling pipe. Based on time that is adjustable separately, filling nozzle is on/off by electromagnetic valve.

Cylinder: AIR TECH Motor: HAITECH Rinsing tank/nozzle: 316L SS Structure: SUS304 SS

Filling nozzle is no dead-angle polished Independent filling level adjust unit for each filling nozzle. No overflow water. Minimizing over-flow (almost no overflow). Constant water level.


--------------------------------------------------------------------------------------------------------------------------------

Page 18 of 32

Driven by cylinder, filling nozzle inserts down until close to the bottle bottom, then the nozzle is open to fill water, minimizing bubble.

Capper Moving bottle catch suspending cap. While it goes through an incline capping belt, cap is pressed evenly.

Motor: HAITECH Sensor: BANNER SUS304 SS

Compatible for variety of bottle height.

Cap washer Coming from cap feeder, cap is sent to unscrambler on the top of cap washer, where it is organized in order. Then cap goes into cap washer through a chute. Rinsing nozzle sprays sterilizing liquid and drinkable water thoroughly to clean cap. Washing stage includes drinkable water, sterilizing liquid, drip. Then cleaned cap goes to capper via another chute.

Pump: Wilo Rinsing tank/pipe/nozzle: 316L

Cylinder: AIR TECH Sensor: BANNER

Fully automatic, ensuring disinfection effect. No dead angle rinsing.

Cap feeder Cap is put into cap container manually, then it is sent to cap washer automatically by air blow.

SUS 304SS Sensor: BANNER

Cap lack alarm. Automatic operation.


--------------------------------------------------------------------------------------------------------------------------------

Page 19 of 32

8. PHOTOS OF LINEAR 5 GALLON BOTTLING LINE

8.1 Decapper


--------------------------------------------------------------------------------------------------------------------------------

Page 20 of 32

8.2 Linear Outer Washer


--------------------------------------------------------------------------------------------------------------------------------

Page 21 of 32


--------------------------------------------------------------------------------------------------------------------------------

Page 22 of 32

8.3 14-Stages Inner Washer


--------------------------------------------------------------------------------------------------------------------------------

Page 23 of 32

8.4 Rinsing Nozzle

Patented multi-layer rinsing nozzle supplies multi-layers liquid spray, which

ensure chemical reaches all inside bottle without leaving dead angle. This

rinsing nozzle is applied on the disinfectant washing stage.


--------------------------------------------------------------------------------------------------------------------------------

Page 24 of 32

Patented taper shape rinsing nozzle supplies water evase water flow +

central flow. It is specially used at final water rinsing, achieving complete

washing effect, at the same time save quantity of water.


--------------------------------------------------------------------------------------------------------------------------------

Page 25 of 32

BACK TO INNER WASHER


--------------------------------------------------------------------------------------------------------------------------------

Page 26 of 32

8.5 Filler

“ ”shape filling tank avoids dead angle and supplies the same pressure

to each filling nozzle, which makes the water level of each bottle constant.

Another obvious advantage of this filling principle is, there is no overflow at

all, avoid any waste of water


--------------------------------------------------------------------------------------------------------------------------------

Page 27 of 32

8.6 Cap Washer


--------------------------------------------------------------------------------------------------------------------------------

Page 28 of 32

8.7 Cap Feeder

8.8 Optional Automatic Chemical Dosing System

It monitors the concentration of detergent/disinfectant and adds chemical

if concentration is low

Proposal for 600BPH 5 Gallon Bottle Filling line

Page29of32

8.9 Food-Grade Chemical Tanks with Manhole

Proposal for 600BPH 5 Gallon Bottle Filling line

Page30of32

8.10 Air Filter

• High efficiency air filter (FFU) on the top of filling chamber ensures the

product hygiene.


--------------------------------------------------------------------------------------------------------------------------------

Page 31 of 32

8.11 Water Supply Station


--------------------------------------------------------------------------------------------------------------------------------

Page 32 of 32

Ozone Mixer

Documents

CAPACITY: 600BPH 5 GALLON BOTTLING LINE PROPOSAL …timmex-bg.com/.../08/Proposal_of_600BPH_5_Gallon_Bottling_Line_10 … · CAPACITY: 600BPH 5 GALLON BOTTLING LINE ... Proposal for