When an Indian brewery first reached out to us about a 3000 CPH beer can filling line, their first question was surprisingly simple:
“Can one line really handle 195ml, 250ml, 330ml, and 500ml cans without becoming a daily headache?”
It’s a fair question — and honestly, a smart one.
From our experience, most problems with multi-size beer canning lines don’t appear on day one. They show up six months later, when operators are tired and changeovers start going wrong.
Why the Customer Didn’t Want Separate Lines
At the beginning, the customer considered buying two smaller machines.
After a few calls, they shared their real concern:
“We don’t want high speed. We want something our team can actually run.”
With a target output of 3,000 cans per hour, flexibility and reliability mattered more than maximum automation.
This is a very common situation for Indian breweries entering can packaging.
The Four Can Sizes That Made the Project Interesting
The line needed to run:
- 195ml cans for promotional packs
- 250ml for local retail
- 330ml as the main volume
- 500ml for export orders
Different heights, same beer, same shift.
That combination is exactly where a well-designed beer can filling line either proves its value — or causes frustration.
The First Real Discussion: Can Rinsing Comes Before Filling
Most buyers focus on the beer can filling machine first.
This customer didn’t — and that helped a lot.
They asked:
“Will short cans like 195ml be stable during rinsing?”
That question told us they were thinking ahead.
How We Designed the Can Rinser
We used one multi-line can rinsing machine, with:
- 4 guides for different can heights
- Simple gripping inserts for short and tall cans
- Fixed rinsing time that works across all four sizes
Instead of separate machines, we designed simple and easy.
When we explained this, the customer’s response was:
“Good. We don’t want something complicated.”
Filling Was Where They Were Most Nervous
Their biggest worry was foam.
“If we change from 195ml to 500ml, will we have filling problems?”
That’s where the counter-pressure beer can filling machine made the difference.
What We Did Differently
- Adjustable lifting height with clear reference marks
- Same filling valves for all can sizes
- CO₂ purging before filling
- Stable centering, even for short cans
We didn’t promise miracles.
We promised repeatability.
Change Parts: Less Than the Customer Expected
One moment I still remember clearly:
“Do we need four sets of filling valves?”
The answer was no.
For this multi-size beer can filling line, the change parts were limited to:
- Lifting pads
- Guide adjustments
- Seamer tooling
The filling valves stayed the same.
You could hear the relief in the next call.
How Long Does Size Change Actually Take?
After installation and training, the customer tested it themselves.
- Small cans (195ml ↔ 250ml ↔ 330ml): about 20–30 minutes
- From small cans to 500ml: around 40–50 minutes
Their feedback was simple:
“This is manageable for our team.”
That’s usually the best compliment an engineer can get.
Why 3000 CPH Was the Right Speed
At 3000 CPH, the line is fast enough for commercial production but slow enough to remain:
- Easy to maintain
- Forgiving for operators
- Stable under local power conditions
For many breweries, a 3000 CPH beer canning line is where long-term stability begins.
Looking Back: What Made This Project Work
It wasn’t one big technical breakthrough.
It was small decisions:
- Designing rinsing before filling
- Limiting unnecessary change parts
- Avoiding over-automation
- Thinking about the people running the line, not just the machine
That’s what turns a beer can filling line into a production tool, not a daily problem.
Final Thought for Breweries Planning Multiple Can Sizes
If you’re planning to run 195ml, 250ml, 330ml, and 500ml cans on one beer can filling line, don’t ask only:
“Can it do it?”
Ask:
“Can my team do it every day?”
That question usually leads to better engineering decisions.
Planning a Multi-Size Beer Can Filling Line?
If you’re considering a beer canning line for multiple can sizes, especially in India or similar markets, share your:
- Required capacity (CPH)
- Can sizes
- Beer type
- Available space
We’ll help you design a line that works in real life, not just on paper.
