Syrup Filling Line

Syrups, widely used in pharmaceuticals, nutraceuticals, and food & beverage industries, demand strict control over filling accuracy, hygiene, and packaging integrity to ensure product quality and shelf life. The integrated syrup filling line, composed of five core pieces of equipment—Bottle Unscrambler, FCM Liquid Filling and Capping Machine, Automatic Measuring Cup Placing Machine, Labeling Machine, and Cartoning Machine—realizes a fully automated workflow from empty bottle handling to finished cartoned products. This system not only addresses the viscosity and sterility requirements of syrup products but also enhances production efficiency and regulatory compliance, becoming a core solution for manufacturers pursuing high-standard liquid packaging.

Core Equipment and Workflow Coordination

1. Bottle Unscrambler: The Starting Point of Orderly Packaging

As the first step in the filling line, the Bottle Unscrambler is designed to sort and orient disorganized empty bottles into a uniform, upright sequence, laying the foundation for subsequent filling and capping processes. Engineered for syrup packaging scenarios, it accommodates various bottle types (e.g., glass, PET) and sizes, from small oral syrup bottles to large-volume containers. The machine uses mechanical agitation and guide rails to gently arrange bottles, avoiding scratches or damage to the bottle surface—critical for maintaining product aesthetics and preventing contamination risks.

Equipped with variable speed control, it synchronizes seamlessly with the downstream filling machine, eliminating bottlenecks. Its enclosed structure prevents dust and external pollutants from entering the bottle, complying with GMP (Good Manufacturing Practices) requirements. Additionally, the quick-change design allows easy adjustment for different bottle specifications, supporting flexible production of multiple syrup formulations.

Suitable Specification:3-1000ml

Suitable Bottle Dia.:φ10-φ80mm

Suitable Bottle Height:85-300mm

Capacity:0-100 bottles/min (speed is adjustable)

Voltage:220v50hz

Power:0.5kw

Weight: 50KG

Overall size: 600*600*1000mm

2. FCM Liquid Filling and Capping Machine: Core of Precision and Sealing

The FCM Liquid Filling and Capping Machine integrates two key functions—syrup filling and bottle capping—into one unit, optimizing space and improving process continuity. Targeting the high viscosity and easy foaming characteristics of syrups, it adopts precision volumetric filling technology (e.g., piston or gear pump filling) to ensure consistent filling volumes, with an accuracy error of less than ±1%, meeting strict dosage standards for pharmaceutical and food syrups.

The filling nozzles feature anti-drip and anti-foaming designs, minimizing syrup waste and ensuring bottle mouth cleanliness. After filling, the machine automatically conveys bottles to the capping station, where it performs screw capping, press capping, or snap capping based on cap types (e.g., plastic screw caps, aluminum caps). It applies uniform capping torque to guarantee hermetic sealing, preventing syrup leakage and oxidation. Constructed with food-grade stainless steel, all parts in contact with syrup are easy to disassemble and clean, avoiding cross-contamination and adhering to hygiene regulations.

1. SS piston pump fills high precision suitable for oral liquid and light liquid with viscosity.

2. This machine is compact design, streamline bottle conveying, more stable.

3. No bottle no fill function.

4. Auto frequency conversion adjusting speed.

5. Auto display and count.

6. Rolling sealer uses single flexible knife with 12 rolling heads, one machine can auto entry, filling, adding cap, and sealing smoothly.

7. One machine can auto entry, filling adding capper, and sealing.

8. The whole machine is designed according to the requirements of GMP.

3. Automatic Measuring Cup Placing Machine: Standardized Dosage Accessory Handling

For syrups requiring precise dosage (e.g., pediatric syrups, medicinal syrups), the Automatic Measuring Cup Placing Machine is an indispensable accessory. It automatically feeds, orients, and places measuring cups into bottle necks or cartons, ensuring each product is equipped with a matching dosage tool. The machine uses optical sensors to detect cup presence and position, rejecting defective or misaligned cups to maintain packaging consistency.

Its flexible design adapts to different measuring cup sizes and shapes, and it synchronizes with the capping and labeling processes to avoid production delays. The closed feeding system prevents dust contamination of measuring cups, and the machine’s simple operation interface allows operators to adjust parameters quickly for recipe changes, enhancing production flexibility.

Bottle specifications: height 45-150mm, diameter: φ20-φ100 (square bottle, flat bottle, round bottle are all available)

Measuring cup specifications: outer diameter φ18-50mm

Carton height (L): 20-300mm

Maximum speed: 300pcs/min

Conversion specification time: 5-20min

Working mode: continuous

Voltage: φ3 -380V

Total power: about 1.1KW

Compressed air pressure: 4-6Bar

Control: PLC

Dimensions: 1100*900*2230mm

Total weight: about 650KG

4. Labeling Machine: Product Identification and Compliance

The Labeling Machine is responsible for applying clear, accurate labels to syrup bottles, conveying product information (e.g., ingredients, dosage, expiration date) and ensuring regulatory compliance. Designed for curved bottle surfaces (glass or PET), it adopts self-adhesive labeling technology with high positioning accuracy, ensuring labels are flat, wrinkle-free, and aligned consistently.

Equipped with a coding module, it can print variable data (e.g., batch numbers, production dates) directly on labels or bottles, enabling full product traceability. The machine supports various label materials (e.g., waterproof paper, BOPP film) to withstand the storage environment of syrups (e.g., refrigeration, humidity). Quick label changeovers and easy calibration reduce downtime when switching between product SKUs, improving line adaptability.

Labeling precision: ±1mm (Errors of products and labels are not included.) and adjustment level will influence labeling precision obviously;

Labeling speed: 0-100 pcs/min (related with product label dimensions).

Applicable product: containers provided by customer.

Applicable label: rolled label provided by customer

Machine dimension: 1930×1110×1520mm (length×width×height).

Applicable power: 220ACV 50/60HZ

Machine weight: 185Kg.

5. Cartoning Machine: Final Packaging and Protection

The Cartoning Machine completes the final step of the syrup filling line, automatically packing labeled bottles into cartons, providing secondary protection and facilitating storage and transportation. It integrates carton forming, bottle loading, leaflet inserting (optional), and carton sealing functions into a single automated process, eliminating manual handling and reducing labor costs.

The machine uses mechanical arms or pushers to gently load bottles into cartons, avoiding bottle damage or label scuffing. It can handle different carton sizes and styles (e.g., tuck-end, glue-sealed) and is equipped with detection systems to ensure each carton contains the correct number of bottles and leaflets. The sealed cartons are stable and neat, meeting logistics and retail packaging requirements. Additionally, the machine’s modular design allows easy integration with upstream equipment and downstream palletizing systems, forming a complete packaging line.

Key Advantages of the Integrated Syrup Filling Line

- Precision and Hygiene Assurance: Targeted designs for syrup viscosity (anti-foaming filling, hermetic capping) and food-grade materials ensure dosage accuracy and product sterility, complying with GMP, FDA, and other international standards.

- Fully Automated Workflow: From bottle unscrambling to cartoning, the line eliminates manual intervention, reduces human error, and increases production capacity—suitable for large-scale syrup manufacturing.

- Flexible Production Capacity: All equipment supports quick parameter adjustments and format changes, adapting to different bottle sizes, syrup formulations, and packaging designs (e.g., with/without measuring cups, different carton styles).

- Traceability and Compliance: Integrated coding and labeling functions enable full traceability of production batches, simplifying audit processes and ensuring compliance with product information disclosure regulations.

- Cost-Efficiency: Reduced material waste (precision filling), labor costs (automation), and downtime (quick changeovers) deliver long-term cost savings, while stable packaging quality reduces rework and recall risks.

Conclusion

The syrup filling line, integrated with Bottle Unscrambler, FCM Liquid Filling and Capping Machine, Automatic Measuring Cup Placing Machine, Labeling Machine, and Cartoning Machine, is a high-performance solution tailored to the unique requirements of syrup packaging. By combining precision engineering, hygiene design, and full automation, it balances production efficiency, product quality, and regulatory compliance, meeting the evolving needs of pharmaceutical, nutraceutical, and food & beverage manufacturers. As consumers and regulators continue to raise standards for liquid products, this integrated line will remain a key driver of innovation and excellence in syrup production and packaging.