Custom Filling Solution Enables Uruguayan Factory to Double Output and Greatly Cut Downtime
This case study thoroughly sorts out the customer’s production challenges, tailored customized solutions, on-site commissioning procedures, and authentic user feedback.
Basic Project Information
|
Item |
Details |
|
Customer Country |
Uruguay (Montevideo) |
|
Factory Establishment Year |
2016 |
|
Applicable Beverages |
Fruit juice, purified water (500ml PET plastic bottles) |
|
Pre-upgrade Production Capacity |
Approximately 1,800 bottles per hour (BPH) |
|
Target Production Capacity |
≥ 4,000 BPH |
|
Full Production Line Configuration |
Existing bottle unscrambler → MIC-ZQG-2020 filling machine supplied by us → Existing capping machine → Existing labeling machine → Existing shrink wrapping machine |
|
Order Quantity |
1 set of bottle filling machine |
| Order Date |
June 10, 2021 |
|
Shipping Method |
Ocean freight from Ningbo Port, China to Montevideo Port, Uruguay |
|
Total Purchase Cost |
USD 4,560 (Ex Works / EXW) |
Customer Requirements & Existing Pain Points
1. Insufficient Production Capacity: The old equipment's maximum output was merely 1,800 BPH, but new orders required a minimum throughput of 4,000 BPH. Because of this gap, the factory had to schedule frequent overtime shifts, which drove up continuous labor expenses.
2. Unqualified Sterility: The filling zone lacked integrated CIP (Clean-in-Place) piping and sealing protection. Consequently, 3% to 5% of every production batch suffered microbial contamination, which repeatedly triggered product recalls and raw material wastage.
3. Frequent Equipment Breakdowns: Aging pneumatic components caused random daily shutdowns. Maintenance occupied 3 to 4 hours weekly, and spare parts procurement proved difficult.
4. No Remote After-sales Support: The previous machinery supplier offered no maintenance services, so every malfunction required the costly hiring of local repair technicians.
A verbatim summary from the plant manager stated: "We needed a filler that could run stably for 8 consecutive hours with zero leakage and complete full cleaning within 15 minutes. Meanwhile, we hoped our partner could provide steady, reliable after-sales support across oceans."
Customized Solution
Following multiple rounds of remote online communication and verification of bottle samples sent by the client, we custom-developed the MIC-ZQG-2020 automatic bottle filling machine. It is purpose-built for small and medium juice and drinking water producers who prioritize sanitation and easy operation.
Core Equipment Advantages
2. Integrated CIP Cleaning Pipeline: This enables complete pipeline sanitization without equipment disassembly, and it fully meets food-grade sterility standards.
3. Adjustable Filling Nozzles: These are custom-calibrated for 500ml PET bottle necks, and they ensure filling accuracy is controlled at ±1.5ml.
4. Full SUS304 Stainless Steel Construction: This material is rust-proof and corrosion-resistant, and it is convenient for daily sanitization.
5. Automatic Liquid Level Sensor: This stabilizes the liquid tank volume and prevents foaming and overfilling.
6. Small Footprint: The machine occupies only 2.5 square meters, so it fits seamlessly into the original workshop layout.
Apart from the main unit, we delivered supporting services as follows:
2. Full video-guided remote commissioning, and an on-site engineer was dispatched within 10 days after the goods arrived at the Uruguay port.
3. Spanish-language operation and maintenance manuals.
Related links:
On-site Installation, Commissioning & Production Performance
Our senior engineer arrived in Montevideo on July 15, 2021, and finished mechanical assembly, no-load testing, and material trial runs within 5 working days.
Pre & Post Upgrade Performance Comparison
|
Indicator |
Before Upgrade |
After Upgrade |
|
Production Speed (BPH) |
1,800 |
Stable 4,200; peak 4,500 |
|
Filling Accuracy Tolerance |
±5 ml |
±1.2 ml |
|
Weekly Unplanned Downtime |
Around 4 hours |
Less than 20 minutes |
|
Sanitation Pass Rate |
95% |
99.8% |
|
On-site Operators |
2 workers |
Only 1 operator for semi-automatic supervision |
No unplanned shutdowns occurred during 8-hour shifts in the first week after commissioning. Furthermore, the customer was highly satisfied with the CIP system because the entire fluid path finished cleaning in under 12 minutes, which enabled rapid production switching between juice and drinking water.
Authentic Customer Testimonial
"We felt hesitant about cooperating with an unseen Chinese supplier at first, yet MIC Machinery far exceeded all expectations. The machine arrived intact with robust packaging, installation proceeded efficiently, and operational performance stands outstanding. Our output has more than doubled, and no contamination incidents have taken place since launch. Remote after-sales response is prompt; technicians adjusted filling speed for us within one hour via WhatsApp. We plan to purchase a second unit for our new sparkling water line."
The client also recorded a short operation video, praising the low running noise and effortless cleaning. They concluded, "At this price point, machine performance matches premium European brands. We highly recommend MIC."
Ready to Upgrade Your Filling Line?
1. Secure customized capacity quotation: Submit bottle parameters and target throughput, and we will issue a formal quote within 24 hours.
[Request a Quote]
MIC Machinery Technology Co., Ltd — Trusted global provider of filling solutions for beverage manufacturers
ISO 9001 & CE certified; over 15 years of export experience serving Latin America, Europe, Southeast Asia and other regions.