To guarantee quality, safety and performance, a bottling line must be designed according to the specific characteristics of the liquid being bottled. Each product has its own requirements. Strong alcohol, hot juice or ‘No Low’ drinks (low or no alcohol) are not bottled in the same way. Here’s how to adapt the bottling line for perfectly controlled production.
Bottling strong spirits: resistance and safety above all
Spirits (rum, gin, whisky, brandy, etc.) require equipment capable of withstanding high alcohol content while ensuring filling without loss or evaporation.
- For rinsing, equipment can be installed that allows rinsing with alcohol (with a rinsing product recycling device), which has the advantage of avoiding clear water residues that would reduce the alcohol content in the final product: this is known as avinage.
- The use of 316L stainless steel pipes and tanks also prevents corrosion.
- Strong spirits often come in non-standard bottle sizes. For filling, we can install special selection stars and other centring equipment to ensure that these flat or square bottles can be processed.
Bottling ‘No Low’ beverages: precision, hygiene and aroma stability
The market for non-alcoholic (‘No’) and low-alcohol (‘Low’) beverages is booming. These products require special attention, as they combine high aromatic requirements with increased microbiological sensitivity.
Without the natural preservative effect of alcohol, ‘No Low’ beverages are more susceptible to microbiological contamination, oxidation and flavour deterioration. To protect this type of product during bottling, we recommend using:
- Effective disinfection: for example, we offer the option of installing a 3-phase disinfection cycle (chemical sterilisation + rinsing with sterile water + inerting with neutral gas or steam injection) on our bottling lines.
- Extended drainage times: these help to limit residues before filling.
- Precise control solutions: flow meter, injection control, precise temperature control, automatic shut-off in case of product shortage, shutter to ensure product stability.
- Neutral and hygienic materials (stainless steel, food-grade seals): to prevent contamination.
More information on No Low bottling: More delicate beverages, a more demanding process.
Bottling hot juices and pasteurised drinks: maximum heat resistance and hygiene
Fruit juices and hot drinks require circuits capable of withstanding high temperatures while maintaining product safety. For this type of product, it is recommended that bottling lines be equipped with:
- « Special juice » nozzles fitted with special seals capable of handling this type of sensitive product.
- Filling systems that maintain temperature during bottling and can also handle thicker juices.
- Capping suitable for each bottle.
Line layout: optimising space and productivity
The performance of a bottling line depends not only on the machines, but also on the layout of the workshop.
Depending on the configuration of the site, several layouts are possible:
- A longitudinal bottling line: ideal for narrow spaces and continuous flows.
- A U-shaped bottling line: allows for visual feedback and rapid quality control.
- A bridge bottling line (or bottle lift): to free up floor space and facilitate cleaning.
- Centralised control via a touch screen to monitor speed and performance, as well as cleaning and filling stages.
Tailor-made support with Costral
Every bottling project is unique. At Costral, we support you from design to commissioning, with:
- A technical study tailored to your products and volumes;
- A selection of components suited to your liquids;
- Manufacturing, assembly and adjustment of the complete line;
- Training operators in use and maintenance.
Need a technical study or a personalised ?
Contact us as soon as possible! We design bottling lines tailored to your products (wine bottling lines, beer bottling lines, bottling lines for spirits and strong alcoholic beverages, juice bottling lines) at your pace and in your production space.