Packaging Line Project
Automatic Mango Juice Filling and Capping Line in Chiang Mai, Thailand
This mango juice bottling line was configured for a producer in Chiang Mai, Thailand. The connected 14 m line combines automatic bottle unscrambling, a 10-head tracking servo filling machine, automatic cap feeding and a double-head four-wheel capping machine.
The project test record covers 3,000 bottles in total, including a 30-minute continuous run. Reported results were a filling error of ±0.5–1.0%, no dripping, 100% capping pass rate and no leakage. After six months of use, the customer reports normal operation, simple controls and stable production.
- Product
- Pulp-free mango juice in rectangular plastic bottles with 35 mm HDPE screw caps
- Customer Target Output
- Recorded video reference: 1 L per bottle in approximately 8 seconds; 4,500 bottles per hour for the shown 10-head setup.
- Designed Line Capacity
- Recorded output reference: 4,500 bottles per hour for the shown 10-head configuration
- Country / Region
- Chiang Mai, Thailand
Automatic Mango Juice Bottle Filling and Capping Line with 10-Head Servo Filler
Project Overview
Key project data for equipment selection and line planning.
- Application / Industry
- Mango Juice Production
- Country / Region
- Chiang Mai, Thailand
- Product
- Pulp-free mango juice in rectangular plastic bottles with 35 mm HDPE screw caps
- Customer Target Output
- Recorded video reference: 1 L per bottle in approximately 8 seconds; 4,500 bottles per hour for the shown 10-head setup.
- Designed Line Capacity
- Recorded output reference: 4,500 bottles per hour for the shown 10-head configuration
- Project Location
- Chiang Mai, Thailand
- Container
- Rectangular plastic bottle; 32 mm bottle opening
- Cap
- HDPE screw cap; 35 mm diameter × 15 mm height
- Filling Machine
- LEKA-FLSF-10-C 10-head tracking servo filling machine; project unit power 3.5 kW
- Capping Machine
- Double-head four-wheel capping machine for 35 mm caps
- Line Scope
- Bottle unscrambling, filling, cap feeding, capping and connected conveying
- Line Length
- 14 m
- Electrical Supply
- 220 V; 11 kW total connected line power
- Recorded Filling Reference
- 1 L per bottle in approximately 8 seconds; 4,500 bottles per hour for the shown 10-head setup
The 3,000 bottles refer to the total project test quantity. The 30-minute value refers to one continuous running test and is not presented as the time required to fill all 3,000 bottles. Final output depends on fill volume, product properties, bottle spacing, cap handling and line settings.
Customer Requirements
What the customer needed the line to handle and achieve.
The project required a complete automatic line for pulp-free mango juice, using rectangular bottles with a 32 mm bottle opening and 35 mm HDPE screw caps.
The line needed stable bottle feeding, controlled filling without visible bubbles, automatic cap feeding, reliable four-wheel cap tightening and simple operation for daily production.
Customer Challenge and Project Goal
The production constraints that shaped the proposed solution.
Production Challenge
The customer needed a cost-effective complete line that was easy to operate and could maintain stable production.
Filling accuracy, clean nozzle cut-off, cap feeding, four-wheel tightening and finished-bottle leakage control were treated as connected acceptance points.
Required Improvement
The project needed to connect bottle feeding, filling, cap placement and tightening into one stable workflow.
Key package constraints included the rectangular bottle, 32 mm bottle opening, 35 mm cap diameter and 15 mm cap height, while filling quality required controlled cut-off, no dripping and no visible bubbles.
Why This Configuration Was Selected
How the product, package and output target influenced equipment selection.
The 10-head tracking servo filler supports continuous bottle movement and the required filling output, while automatic bottle and cap handling reduces manual work.
The double-head four-wheel capping machine matches the 35 mm screw cap and supports stable tightening.
The complete configuration gives the customer one coordinated line instead of separately matched machines.
Complete Line Configuration
The machines and functions included in the proposed packaging process.
| Machine Configuration | Model | Production Use | Project-Specific Requirement |
|---|---|---|---|
| Automatic Bottle Unscrambler | Project-specific | Orients and feeds empty rectangular bottles into the connected line. | Configured for the supplied rectangular bottle footprint, bottle stability and line direction. |
| 10-Head Tracking Servo Filling Machine | LEKA-FLSF-10-C | Fills pulp-free mango juice while the filling heads track the moving bottles. | Configured for the actual product, 1 L filling reference, 3.5 kW project unit power, clean nozzle cut-off and stable bottle transfer. |
| Automatic Cap Feeder | Project-specific | Sorts and supplies 35 mm HDPE screw caps before capping. | Matched to the 35 mm cap diameter, 15 mm cap height and cap orientation. |
| Double-Head Four-Wheel Capping Machine | Project-specific | Uses four-wheel tightening for 35 mm screw caps after filling. | Matched to the 32 mm bottle opening, cap engagement, bottle support and required tightening result. |
| Connected Conveyor System | Project-specific | Transfers bottles through unscrambling, filling, cap feeding and capping across the 14 m line. | Guide rails, conveyor height and accumulation were matched to the supplied package and factory layout. |
More Factory Testing and Production Evidence
Additional project videos and images show package handling, machine operation and finished-product quality.
Quality Control and Project Results
Verified factory-test and acceptance information for this packaging line.
Reported in the supplied project test record.
Total quantity tested across the project test record.
One continuous running test; separate from the total 3,000-bottle quantity.
Displayed in the published test video overlay for the shown filling setup.
Displayed in the published video for the shown 10-head setup.
Reported in the supplied project test record.
Reported for the 35 mm four-wheel capping test.
Reported after capping.
HDPE screw-cap package supplied for the project.
Quality Inspection
The supplied project test record covers 3,000 bottles in total and includes one 30-minute continuous run. Reported filling error was ±0.5–1.0%, with no dripping. For 35 mm caps tightened by the four-wheel capping section, the reported pass rate was 100%, with no leakage observed.
Acceptance Result
Project test record: 3,000 bottles tested in total; one 30-minute continuous run; filling error ±0.5–1.0%; no dripping; 35 mm caps tightened by four wheels; 100% capping pass rate; no leakage.
Project Result Summary
The project delivered a connected 14 m mango juice bottling line for Chiang Mai, Thailand.
The supplied test record reports ±0.5–1.0% filling error, no dripping, 100% capping pass rate and no leakage across a 3,000-bottle test quantity, including one 30-minute continuous run.
After six months of operation, the customer reports normal performance, simple operation and stable production.
Customer Feedback
After six months of use, the customer reports that the line is operating normally, is simple to operate and supports stable production.
How the Packaging Line Works
The connected production sequence from container infeed to finished product.
Automatic Bottle Unscrambling
Orient rectangular bottles and feed them onto the connected conveyor.
Bottle Spacing and Positioning
Stabilize bottle spacing before the tracking filling section.
10-Head Tracking Servo Filling
Fill pulp-free mango juice while the filling heads follow the moving bottles.
Automatic Cap Feeding
Sort and deliver 35 mm HDPE screw caps to the filled bottles.
Double-Head Four-Wheel Capping
Support each bottle and tighten the screw cap using four-wheel capping.
Finished-Bottle Discharge
Transfer capped bottles for leakage checks and downstream packing.
Key Engineering Features
Project-specific functions that improve stability, accuracy, safety and ease of operation.
10-Head Tracking Servo Filling
Ten filling positions track the bottle flow during the mango juice filling process.
Controlled Filling Result
The project test record reports ±0.5–1.0% filling error, no dripping and no visible bubbles.
Automatic Bottle and Cap Handling
Bottle unscrambling and cap feeding reduce manual handling before filling and capping.
Four-Wheel Cap Tightening
The double-head capping section uses four-wheel tightening for the supplied 35 mm caps.
Package-Specific Setup
Bottle guides, cap feeding and capping settings were matched to the 32 mm bottle opening and 35 mm × 15 mm cap.
Integrated 14 m Line
The connected equipment and conveyors form one coordinated filling and capping workflow.
Packaging Specifications
Container, closure and labeling details considered during line configuration.
Container Type
- Bottle
Container Shape
- Square Bottle
- Sample Required
Cap Type
- Screw Cap
Delivered Equipment and Line Scope
The supplied equipment and integration boundary for this project.
The supplied line includes automatic bottle unscrambling, LEKA-FLSF-10-C 10-head tracking servo filling, automatic cap feeding, double-head four-wheel capping and connected conveying across an overall line length of 14 m.
Operation, Changeover and Site Requirements
Information used to plan cleaning, package changeover, utilities and installation.
Materials, Cleaning and Safety
The tested product was pulp-free mango juice, and no visible bubbles were reported during filling. A numerical viscosity value was not supplied, so product viscosity, filling temperature, cleaning method and food-contact requirements should be confirmed from production samples before repeating or adapting this configuration.
Changeover and Optional Equipment
Package changeover can include filling-recipe adjustment, nozzle height, bottle guide rails, cap feeder settings and capping height. Any new bottle or cap should be sample-tested before production. Coding, labeling, inspection and secondary packing can be integrated according to the finished package and factory layout.
- Overall Line Length
- 14 m
- Electrical Supply
- 220 V
- Filling Machine Power
- 3.5 kW
- Total Line Power
- 11 kW
- Compressed Air
- 0.6–1.0 MPa
Delivery and Technical Support
Support available for installation, commissioning, training and continued operation.
LEKA supports product and package review, complete-line configuration, factory testing, layout planning, operating documents, remote commissioning guidance and spare-parts planning.
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