Inside ZONESUN: Assembly and Testing of a Custom Alcohol Bottle Packaging Line
A reliable packaging line is built long before the first bottle enters the conveyor. For a recently completed project for a customer in Korea, the ZONESUN engineering and assembly team integrated a custom packaging line for 500 ml round glass bottles containing a low-viscosity alcohol product.
The line was arranged for left-to-right operation and achieved an actual output of 16 bottles per minute during continuous testing with the customer’s bottles, wooden corks and product.
Project Configuration
The completed system combines bottle feeding, gravity filling with liquid suck-back, wooden cork feeding and pressing, pressure-sensitive labeling, and top capsule heat shrinking.
- Product: Low-viscosity alcohol liquid
- Container: 500 ml round glass bottle
- Closure: Wooden cork with top capsule
- Tested output: 16 bottles per minute
- Line footprint: Approximately 12.7 m × 2 m
- Power supply: 220 V / 50 Hz
- Conveyor direction: Left to right
Equipment Included in the Line
- ZS-CB190 Bottle Infeed Unit – organizes and feeds the glass bottles into the packaging line.
- ZS-VTGZ100 Gravity Filling Machine – configured with four filling heads, pump feeding and liquid suck-back for this project.
- ZS-XG16D1 Wooden Cork Pressing Machine – customized according to the customer’s wooden cork dimensions.
- ZS-TB260R Bottle Labeling Machine – applies pressure-sensitive labels to the round glass bottles.
- ZS-SXRS1 Capsule Heat Shrinking Machine – completes the top capsule application and heat shrinking process.
1. Mechanical Assembly and Station Setup
Assembly began with the machine frames, stainless steel enclosures and working mechanisms. ZONESUN technicians installed and aligned the mechanical components according to the engineering drawings, then checked that each station could be adjusted around the customer’s bottle and closure dimensions.
For the corking section, the feeding and placement structure was configured according to the wooden cork samples supplied by the customer. The capsule feeding tooling was also produced according to the customer-provided sleeve samples.
2. Electrical Cabinet Wiring and Component Checks
After mechanical installation, the electrical team completed the control cabinet wiring and connected the drives, sensors, actuators and operator controls.
The filling, corking, labeling and capsule shrinking machines use their own control systems. Each machine is equipped with an emergency stop button. Before powered testing, technicians checked the terminal connections, sensor response, motor direction and basic safety controls.
3. Four-Head Gravity Filling System
The ZS-VTGZ100 gravity filling machine was equipped with four filling heads and supplied by a feed pump. The filling nozzles were selected according to the bottle opening to help the liquid enter the containers smoothly.
A suck-back function was incorporated to reduce residual liquid and dripping after each filling cycle. The product-contact components for this project were manufactured from 304 stainless steel.
4. Corking, Labeling and Capsule Shrinking Integration
Once the individual machines were assembled, the team connected them in production order and aligned the conveyor transfer points.
The guide rails, sensors and working positions were adjusted so that the round glass bottles could move steadily between filling, wooden cork pressing, labeling and top capsule shrinking. Particular attention was given to bottle transfer stability and positioning accuracy at each working station.
5. HMI Configuration and Line Commissioning
The operator interfaces were configured in English. During commissioning, technicians checked the movement of each station, sensor response, conveyor stability and coordination between the bottles and working mechanisms.
The line was then tested with the customer’s actual 500 ml glass bottles, wooden corks, capsule sleeves and alcohol product.
6. Continuous Production Testing
During the running test, the engineering team checked the filling process, suck-back performance, cork placement, closure tightness, label position, capsule shrinking effect and bottle transportation between machines.
Continuous operation confirmed stable bottle handling and an actual production rate of 16 bottles per minute. The finished bottles showed secure corks, consistent label placement and a clean overall appearance.
7. Final Inspection and Export Packing
After testing and final acceptance, the equipment was cleaned and protected with wrapping material. The machines were then moved into export wooden cases to protect the installed components and adjusted mechanisms during international transportation.
Engineering Value Behind the Assembly Process
This project demonstrates how ZONESUN turns individual packaging machines into an application-specific production line. The work involves more than placing machines in sequence. Filling nozzle selection, cork feeding tooling, capsule tooling, conveyor alignment, electrical integration and product testing must all be matched to the customer’s packaging materials and production requirements.
For manufacturers planning a similar packaging project, providing representative liquid, bottles, closures, labels and capsule samples before production allows the engineering team to verify compatibility and complete more accurate factory testing.
Important Safety Considerations for Alcohol Products
Electrical and safety requirements depend on the product composition, flash point, production environment and applicable local regulations. Explosion-proof electrical components were not specified for this particular project.
Customers filling flammable liquids should provide the product safety data, flash point and required hazardous-area classification before equipment design. ZONESUN can then evaluate whether explosion-proof components or other special safety measures are required.
Planning a Custom Bottle Packaging Line?
Send ZONESUN your product information, bottle and closure samples, target output, factory layout and electrical requirements. Our engineering team can evaluate the application and recommend a suitable filling and packaging line configuration.