AL-5000 Automatic Liquid Filling Line

Model: AL-5000 Product Name: Automatic liquid filling line Supplier: Wenzhou T&D Packaging Machinery Factory

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The AL-5000 is a fully automatic liquid filling line built by Wenzhou T&D Packaging Machinery Factory. It covers five stations — bottle distributing, filling, cap feeding, capping and labeling — and is designed for plastic bottles with plastic screw caps, such as dishwashing liquid, hand wash and household cleaning products. The standard line consists of three units: the A4-500 automatic piston filling machine (2 heads, 50-500ml), the DC-1 automatic screwing capping machine, and the AL-220 automatic round bottle labeling machine. The bottle distributing machine (80cm rotary table) is listed as an optional device in the factory quotation. The filler runs on a Taiwanese-brand PLC with touchscreen control and Airtac pneumatic components, with filling accuracy of plus or minus 1 percent. German SICK photocell sensors deliver no bottle, no fill operation, and the nozzles use a bottom close positive shut-off design to prevent dripping. The capper runs two capping heads simultaneously; the labeling machine runs at 40–200 pieces per minute with a labeling precision of 1.0mm or better, and stops with an alarm when labels run out or break. Eight filling ranges are available from 5-50ml to 500-5000ml, with 2, 4, 6 or 8 filling heads. Lead time is 30–45 working days, shipment from Ningbo port, with a one-year warranty.

Key Specs at a Glance: Filling range 50–500ml (standard) | Filling speed 10–30 times/min | Filling accuracy ±1% | Filling heads 2 heads (2 / 4 / 6 / 8 optional) | Air pressure 0.6–0.8 MPa | Air consumption 3–4 m³/h | Voltage 220V 50/60Hz 660W | Labeling speed 40–200 pcs/min | Labeling precision ≥1.0mm.

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1. Product Overview

Category

Item	Detail
Equipment category	Automatic bottle distributing, filling, cap feeding, capping and labeling line
English category	Automatic bottle distributing, filling, capping and labeling line
Product compatibility	Liquids; piston filling
Packaging compatibility	Plastic bottles with plastic screw caps; compatible with PET bottles and glass bottles
Applicable bottle diameter	Bottle distributing machine φ20–φ100mm; labeling machine φ32–φ150mm (overlap range for the complete line to be confirmed)
Applicable bottle height	Bottle distributing machine 20–150mm; labeling machine 40–350mm (overlap range for the complete line to be confirmed)
Customization	Special design available on request; machine configuration freely selectable

Applications

• Household Cleaning: dishwashing liquid, hand wash, laundry detergent, windshield washer fluid, disinfectant, toilet cleaner
• Personal Care: shampoo, shower gel, hair conditioner, skin lotion
• Food & Beverage: edible oil, fruit juice, soy sauce, vinegar, seasoning liquids
• Pharmaceuticals & Health Supplements: oral liquids, syrups, rubbing alcohol, supplement oils
• Chemicals & Agrochemicals: pesticide formulations, detergents, car care fluids
• Typical Buyers: household and cleaning product manufacturers, small and mid-size plants producing 5,000–20,000 bottles a day, and contract packers (OEM/ODM) needing bottle body labeling

Core Functions

1. Automatic bottle distributing: rotary table sorts round and square bottles, conveying and counting at 30–200 bottles per minute with infinitely variable speed.
2. Piston dosing filling: fill volume and fill speed are set directly on the HMI, with combined pneumatic and electric drive.
3. Automatic cap feeding and capping: the DC-1 capper runs two capping heads simultaneously, synchronized with the filling cycle.
4. Automatic labeling: the AL-220 round bottle labeling machine applies one or two labels to cylindrical products, using a five-axis positioning label feeding system.
5. No bottle, no fill: German SICK photocell sensors skip filling and capping when a bottle is missing.
6. Automatic alarms: the labeling machine stops and alarms when labels run out or break. An automatic feeding wheel and an automatic receiving device are optional.
7. Expansion interface: can be connected with a semi-auto bottle washer and the PM-168 inkjet printing machine to form a complete packaging line.

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2. Key Advantages

1. Five stations delivered as one line, one purchase covers the whole process: bottle distributing, filling, cap feeding, capping and labeling are supplied and commissioned together, avoiding the timing mismatches and finger-pointing that come with assembling a line from multiple suppliers.
2. Reliable control system: Taiwanese-brand PLC with touchscreen; fill volume and speed are set directly on the HMI. Pneumatic components are Airtac, with combined pneumatic and electric drive for stable running and simple operation.
3. High accuracy, no dripping: filling accuracy is ±1%. The bottom close positive shut-off nozzles eliminate stringing and dripping, keeping bottle necks and bodies clean and leaving the label area uncontaminated.
4. Selectable hygienic grade: stainless steel frame, with 201 stainless steel for the machine body and food-grade 304 stainless steel for product-contact parts, upgradable to 304 or 316 to meet food and personal care hygiene requirements.
5. Efficient capping with no damage to the bottle neck: the DC-1 capper runs two capping heads at the same time, working with SICK photocell sensors so that missing bottles are not processed, with consistent torque.
6. Labeling precision and stability: the AL-220 uses a high-precision stepping servo motor and a five-axis positioning label feeding system, achieving labeling precision of 1.0mm or better with a small label seam error, at 40–200 pieces per minute.
7. Automatic protection against labeling faults: the machine stops and alarms when labels run out or break, preventing unlabeled bottles from reaching the next process and causing rework.
8. Flexible, expandable configuration: choose 2, 4, 6 or 8 filling heads, with eight filling ranges from 5-50ml to 500-5000ml. Bottle washing, coding and glass cover modules can be added.
9. Assured delivery and service: 30–45 working days lead time, wooden case packing suitable for ocean shipping, one-year warranty on the whole machine, and lifetime repair service after the warranty expires.

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3. Technical Specifications

3.1 Standard Line Configuration

NO	Name	QTY	Remark
A	A4-500 2 head automatic filling machine (50-500ml)	1 set	Piston type, 2 heads
B	DC-1 automatic screwing capping machine	1 set	Two capping heads working simultaneously
C	AL-220 automatic round bottle labeling machine	1 set	Labeling of cylindrical products

3.2 A4-500 Filling Machine

Parameter	Value
Model	A4-500
Filling range	50–500ml
Filling heads	2 heads (2 / 4 / 6 / 8 heads optional)
Filling speed	10–30 times/min
Theoretical output	1,200–3,600 bottles/h (calculated from 2 heads × 10–30 times/min, to be confirmed)
Filling precision	±1%
Air pressure range	0.6–0.8 MPa
Air consumption	3–4 m³/h
Voltage / Power	220V 50/60Hz, 660W
Driving mode	Combined pneumatic and electric drive
Control	PLC + touchscreen (Taiwanese brand)
Pneumatic parts	Airtac
Conveyor	2 meters as standard, specification customizable
Frame	201 stainless steel
Contact parts	Food-grade 304 stainless steel (304 / 316 optional)
Anti-drip	Bottom close positive shut-off nozzles
Dimension	110 × 90 × 230cm
Weight	400kg

3.3 Filling Range Options

Filling range	Remark
5–50ml	Optional
10–100ml	Optional
30–300ml	Optional
50–500ml	Standard on this line (A4-500)
100–1000ml	Optional
250–2500ml	Optional
300–3000ml	Optional
500–5000ml	Optional

3.4 DC-1 Automatic Screwing Capping Machine

Parameter	Value
Capping heads	Two heads working simultaneously (two screw lids work at the same time)
Applicable caps	Plastic PET bottle caps, glass bottle caps
Cap feeding	To be confirmed (whether the automatic cap feeding device is included as standard needs confirmation with the factory)
Sensor	German SICK photocell sensors, no bottle no action
Capping speed	Adjustable, matched to the filling machine
Cap diameter	Customizable

3.5 AL-220 Automatic Round Bottle Labeling Machine

Parameter	Value
Labeling precision	≥1.0mm
Speed	40–200 pcs/min
Apply the product diameter	φ32mm–φ150mm
Apply the product height	40–350mm
Apply the label size	Length 20–150mm, Width 10–250mm
Apply labels inside diameter	76mm
Apply labels outside diameter	within 360mm
The machine dimension	2000 × 700 × 1450mm
The machine weight	200kg
Voltage	220V/100V 50Hz/60Hz

Labeling Machine Features

1. Suitable for labeling cylindrical products, applying one or two labels to the same product with high precision and a small label seam error. Can be connected to a production line or used standalone.
2. The machine body is made of stainless steel, and the equipment parts are premium domestic and international brands, for stable performance and a long service life.
3. Widely used in pharmaceutics, daily chemicals, foodstuffs, cosmetics, pesticides, stationery and other industries.
4. Adopts a large human-computer interface with visual display and simple operation.
5. High-precision stepping servo motor for stable performance.
6. Five-axis positioning label feeding system for good stability.
7. When labels run out or break, the machine stops and alarms automatically.
8. Each part is precision machined and specially processed to ensure good quality.
9. An automatic feeding wheel and an automatic receiving device are optional.

3.6 Bottle Distributing Machine (Optional Device)

Parameter	Value
Applicable bottle	Round or square bottle
Desktop diameter	80cm / 100cm / 120cm (80cm in the quotation)
Product diameters	φ20mm – φ100mm
Product height	20mm – 150mm
Conveying speed	30–200 bottles/min, infinitely variable speed
Voltage	220V
Frequency	50Hz
Power	120W
Weight	60kg
Dimension	990 × 900 × 1040mm

3.7 Optional Devices

NO	Name	QTY	Remark
A	Glass Cover	1	Optional, dust protection for the filling zone
B	316 stainless steel of contact material parts	/	Upgrade option, for highly corrosive products
C	Semi-auto bottle washer	1	Optional
D	Bottle distributing machine (80cm diameter rotary table)	1	Optional, required for the five-station line configuration
E	PM-168 inkjet printing machine	1	Optional

3.8 Utilities & Commercial Terms

Item	Detail
Air supply	0.6–0.8 MPa, 3–4 m³/h
Power supply	220V 50/60Hz (filling machine 660W; labeling machine 220V/100V 50/60Hz)
Payment term	30% T/T deposit in advance, 70% balance by T/T before shipment
Shipping methods	Ocean shipping
FOB port	Ningbo port
Delivery time	30–45 working days
Packing details	Wooden case, cuboid, convenient for transportation
Warranty time	One year after start-up in the buyer's factory
Validity period	30 days

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4. Sales Guidance & FAQ

Sales Guidance

1. Establish the fill volume first, then the range: if the customer's product falls outside 50–500ml, select the matching range from the eight options (5-50 / 10-100 / 30-300 / 50-500 / 100-1000 / 250-2500 / 300-3000 / 500-5000ml). Do not force the A4-500 onto it.
2. Establish the output target first, then the head count: 10–30 times/min is the single-cycle speed. Actual bottles per hour = cycles × heads × 60. With 2 heads the theoretical output is 1,200–3,600 bottles/h. For customers needing more, offer 4, 6 or 8 heads.
3. Establish the product viscosity first: this line is built for liquids. Confirm suitability with the factory before committing to high-viscosity pastes. Do not assume.
4. Establish the bottle and cap type first: bottle diameter must satisfy both the bottle distributing machine (φ20–φ100mm) and the labeling machine (φ32–φ150mm), and the same applies to height (20–150mm / 40–350mm). The capping chuck material and torque for plastic screw caps must be confirmed after the customer sends real cap samples.
5. Establish the label specification first: labels of 20–150mm long and 10–250mm wide, with a 76mm core and an outer diameter within 360mm. Self-adhesive label rolls outside this range simply will not load.
6. Align on the output figure: 10–30 times/min is the rated filling cycle value. Actual line output depends on bottle feed rate, product foaming and manual loading. Quote conservatively.
7. Upsell in this order: filling + capping + labeling is the base configuration. For customers needing batch codes, add the PM-168 inkjet printing machine; for customers with cleanliness requirements, add the glass cover and the semi-auto bottle washer.
8. Push hygiene and compliance: lead with 304 contact parts for personal care and food customers, and the 316 upgrade for high-salt or high-acid products. This is the differentiator that supports a price premium.
9. Manage delivery expectations: 30–45 working days plus ocean shipping. State the total lead time up front to avoid disputes after the deposit is paid.

FAQ

Q1: What products is the AL-5000 suited to? This line is built as a liquid filling line, for household and cleaning products such as dishwashing liquid, hand wash, laundry detergent, windshield washer fluid and disinfectant, as well as low to medium viscosity liquids such as edible oil, fruit juice and oral liquids. Suitability for high-viscosity pastes must be confirmed with the factory first.

Q2: What is the output of this line? The filling machine runs at 10–30 cycles per minute. Actual output = cycles × number of filling heads × 60. With the standard 2 heads, theoretical output is 1,200–3,600 bottles per hour (calculated value, to be confirmed). The labeling machine runs at 40–200 pieces per minute, and the actual line rate is set by the slowest station.

Q3: How is filling accuracy guaranteed? Filling accuracy is plus or minus 1 percent, guaranteed by the PLC-controlled piston stroke. The nozzles use a bottom close positive shut-off design to prevent stringing and dripping, so no product contaminates the bottle body and affects labeling.

Q4: What material are the product-contact parts? The standard configuration is food-grade 304 stainless steel, with 201 stainless steel for the machine body. Contact parts can be upgraded to 304 or 316 stainless steel. We recommend 316 for highly corrosive products.

Q5: How many filling heads are available, and what filling ranges can I choose? Filling heads are available in 2, 4, 6 or 8 head versions. Eight filling ranges are available: 5-50ml, 10-100ml, 30-300ml, 50-500ml, 100-1000ml, 250-2500ml, 300-3000ml and 500-5000ml. This line ships with 2 heads and a 50-500ml range as standard.

Q6: Does this line include the bottle distributing machine? It is sold as a five-station line covering bottle distributing, filling, cap feeding, capping and labeling, but in the factory quotation the bottle distributing machine is listed as an optional device. Confirm whether it is included before signing.

Q7: What label and bottle sizes does the AL-220 labeling machine handle? Labels: 20–150mm long, 10–250mm wide, with a 76mm core and an outer diameter within 360mm. Bottles: 32–150mm in diameter, 40–350mm in height. One or two labels can be applied to the same product.

Q8: Can I buy only the filling machine, without the capper and labeling machine? Yes. The machine configuration is freely selectable, and we can supply a single unit to suit your existing line.

Q9: How long is the warranty and what does it cover? One year on the whole machine, starting from start-up and acceptance in the buyer's factory. Parts are supplied free of charge for quality problems during the warranty period; the customer covers freight from China to the destination. If an engineer visit is required, round-trip travel costs are borne by the customer. Lifetime repair service continues after the warranty expires.

Q10: What power and air supply does the customer need to prepare? Power: 220V 50/60Hz (the labeling machine also supports 220V/100V). Air: 0.6–0.8 MPa at 3–4 m³/h. The customer needs to provide an air compressor and a regulated power supply to match.

Q11: Are the values in the specification tables final? The parameters above are for reference only; the actual machine is the standard.

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5. Media & Assets

Video

Content	Link
Machine work process video	https://www.youtube.com/watch?v=J7D7gSl6Yck

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6. Workflow

Station	Action	Role
1. Loading	Operator pours empty bottles onto the bottle distributing machine turntable	Operator
2. Bottle distributing	Turntable sorts and orients round/square bottles, 30–200 bottles/min, infinitely variable speed	Automatic
3. Conveying	Conveyor (2 meters as standard) carries bottles to the filling station; fixing device clamps and locates them	Automatic
4. Filling	Piston filling; fill volume and speed set on the PLC; SICK photocell detection, no bottle no fill	Automatic
5. Cap feeding	Caps are fed and placed in position automatically, synchronized with the capping station	Automatic
6. Capping	DC-1 runs two capping heads simultaneously with consistent torque	Automatic
7. Labeling	AL-220 five-axis positioning label feeding, labeling of round bottles at 40–200 pcs/min	Automatic
8. Optional stations	Semi-auto bottle washing / PM-168 inkjet coding	Automatic
9. Output	Finished bottles discharge to the collection table for manual cartoning	Operator

Pre-operation Setup

1. Connect the 220V 50/60Hz power supply and the 0.6–0.8 MPa air supply (air compressor to be provided by the customer).
2. Set the fill volume (50–500ml) and fill speed on the touchscreen.
3. Adjust the bottle distributing machine turntable speed and conveyor guide rails to suit the bottle diameter and height.
4. Load the caps and trial-cap 3–5 bottles to confirm torque and sealing.
5. Load the label roll (76mm core, outer diameter within 360mm) and trial-label 3–5 bottles to confirm label position and seam.
6. Inspect the fill volume of the first articles (accuracy ±1%), then move to continuous production.

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