Operating Manual – Automatic Bottle Filling Machine
1. Introduction
This manual provides guidance for the safe operation, cleaning, and maintenance of the Automatic
Bottle Filling Machine. The equipment is designed for high-speed filling of carbonated and
non-carbonated beverages into PET or glass bottles.
Intended Use:
Read before operating.
The Bottle Filling Machine consists of the following main components:
4.1 Startup
5.1 Cleaning-in-Place (CIP)
6. Technical Specifications
1. Introduction
This manual provides guidance for the safe operation, cleaning, and maintenance of the Automatic
Bottle Filling Machine. The equipment is designed for high-speed filling of carbonated and
non-carbonated beverages into PET or glass bottles.
Intended Use:
- Filling of liquid products (water, juice, soft drinks, carbonated beverages).
- Operation in a food/beverage-grade manufacturing facility.
- Integration with conveyor, capping, and labeling systems.
Read before operating.
- Only trained personnel may operate the machine.
- Ensure all safety guards and emergency stops are functional.
- Never place hands or tools inside moving parts.
- Disconnect power and compressed air supply before performing maintenance.
- Wear required PPE: safety glasses, ear protection, gloves, and steel-toe footwear.
- Handle cleaning chemicals according to MSDS guidelines.
The Bottle Filling Machine consists of the following main components:
- Infeed Conveyor – transports empty bottles to the filling carousel.
- Starwheel & Guide Rails – positions bottles under the filling heads.
- Filling Valves (12/24/36 heads depending on model) – dispenses liquid into bottles.
- Capping Unit (optional) – applies and tightens caps.
- Outfeed Conveyor – moves filled bottles to labeling/packaging.
- Control Panel (HMI/PLC) – touchscreen interface for monitoring and operation.
- Sensors & Automation – bottle detection, level control, emergency stops.
4.1 Startup
- Verify machine cleanliness and that no foreign objects are present.
- Check utilities: power supply, compressed air, CO2 line (if carbonated), and product line
- pressure.
- Switch ON the Main Power at the control panel.
- Activate the Air Supply.
- Select production recipe on HMI (bottle size, fill volume, speed).
- Press Start Cycle. Machine will self-calibrate.
- Load bottles on the infeed conveyor.
- Monitor filling operation via HMI and visual inspection.
- Ensure bottles are being filled to correct level (automatic level sensors adjust flow).
- Verify caps are correctly applied (if capping is enabled).
- Record production data (batch number, volume, rejects).
- Stop bottle feed.
- Allow remaining bottles to exit.
- Press Stop Cycle.
- Switch off power, air, and product supply.
- Follow cleaning procedure.
5.1 Cleaning-in-Place (CIP)
- Connect CIP line to product inlet.
- Run rinse water cycle (10 min).
- Run caustic solution (as per cleaning schedule).
- Flush with hot water until system is chemical-free.
- Sanitize with approved food-grade disinfectant.
- Inspect filling heads for leaks.
- Check conveyor belts for wear.
- Clean sensors and photo-eyes.
- Lubricate moving parts per lubrication chart.
- Check air pressure regulators and filters.
- Inspect electrical wiring and safety switches.
- Replace gaskets, seals, and O-rings in filling valves.
- Calibrate flow meters and level sensors.
- Perform safety function test.
6. Technical Specifications
- Capacity: 12,000 bottles/hour (330ml)
- Bottle size range: 200ml – 2L
- Filling method: Gravity / Counter-pressure (for carbonated)
- Power supply: 480V, 60Hz, 3-phase
- Air pressure: 6 bar
- Dimensions: 4.5m x 2.2m x 2.5m
- Weight: 3,800 kg
- Filling valve seals
- O-rings
- Conveyor belts
- Sensors (photo-eye, level)
- Lubrication grease (food-grade)
| Issue | Possible Cause | Solution |
| Bottle not filling | No bottle detected / sensor blocked | Clean or adjust bottle sensor |
| Inconsistent fill levels | Air leak in valve / product pressure unstable | Inspect seals, check product pump |
| Spillage during filling | Bottle misaligned / worn guide rails | Adjust starwheel & guide rails |
| Machine won’t start | Emergency stop engaged / low air pressure | Reset E-stop, check air supply |
| Cap not applied properly | Cap feeder jammed / torque set incorrectly | Clear feeder, adjust capping torque |