When beverage producers handle different bottle capacities and neck sizes, one of the biggest challenges is achieving efficient filling on a single machine. Recently, an Argentine customer approached us with a unique requirement: four different bottle sizes – 5L, 8L, 10L, and 20L – to be processed on a linear type 3-in-1 2–2-1 water filling machine.
The bottle specifications were as follows:
- 5L bottlewith a 38mm neck
- 8L & 10L bottleswith a 45mm neck
- 20L bottlewith a 5-gallon cap
Meeting this demand required a customized solution that ensures smooth production without compromising efficiency.
Key Challenges in Multi-Bottle Filling
Different capacities and neck diameters require adjustments in several critical areas:
- Bottle Feeding and Clamping– the system must hold bottles firmly regardless of diameter.
- Filling Valve Adjustment– filling heads need to be adaptable to different bottle heights and neck sizes.
- Capping System– each cap type requires specific handling, especially when bottle neck diameters vary significantly.
Our Customized Technical Solution
To adapt the 2-2-1 linear filling machine to the customer’s needs, we designed the following modifications:
1. Additional Capping Station for 20L Bottles
Since the 20L bottle uses a 5-gallon cap, we added a special capping workstation dedicated to this format. This ensures a secure seal for large bottles without affecting smaller formats.
2. Change Parts for Different Neck Sizes
The 5L bottle (38mm) and the 8L/10L bottles (45mm) require different capping chuck sizes. To accommodate this, we provided interchangeable change parts on the capping machine. This allows operators to switch between formats quickly and reliably.
3. Adjustable Filling Heads and Spacing
The filling module was modified with adjustable spacing between filling heads, making it possible to handle both medium-sized bottles (5L–10L) and the large 20L bottle. The filling valve height adjustment also ensures accurate filling regardless of bottle height.
Advantages of This Multi-Bottle Solution
- Flexibility:One machine handles four bottle types, saving investment in multiple lines.
- Efficiency:Changeover between formats is simple, requiring only quick adjustments and minor change parts.
- Cost-Effective:Instead of buying separate filling machines for 5L–10L bottles and for 20L bottles, the client can use one customized line.
- Scalability:The solution can be further adapted if the client adds more bottle formats in the future.
General Methods for Handling Different Bottles on One Machine
Beyond this case, beverage producers often rely on three main methods to run multiple bottle types on one machine:
- Adjustable clamps and guides – for bottles with slightly different diameters.
- Change Parts (Star Wheels, Chucks, Guides)– used when bottle neck sizes differ significantly.
- Flexible Filling Head Adjustment– allows adaptation to different bottle heights and filling volumes.
For high-end equipment, some manufacturers even use universal gripping systems, which reduce changeover time dramatically.
Conclusion
This Argentine case study shows how one linear type 3-in-1 water filling machine can efficiently handle bottles ranging from 5L to 20L by combining additional workstations, interchangeable change parts, and adjustable filling heads.
With smart engineering, beverage manufacturers can achieve multi-format flexibility, reduce capital costs, and maintain high production efficiency.
