Filling line for bottles of fruit nectar

Industry 02

Juices, nectars and drinks: reconstitution and filling

Reconstituting juice from concentrate, making a nectar or a fruit drink takes the right recipe, controlled heat treatment and a filling line that keeps running.

Beverage plants work from concentrates, purées and flavour bases. Quality is built in the syrup room and at heat treatment; profitability is decided on the filling line, where every minute of downtime is expensive.

We work on new projects (new line, new format) as well as on existing lines: cutting product losses, overlong format changes and non-conformities.

Key process steps

  1. 01

    Raw material receiving

    Concentrates, purées, sugar, treated water; checks and lot traceability.

  2. 02

    Syrup room and blending

    Sugar dissolving, concentrate dosing, Brix and acidity adjustment.

  3. 03

    De-aeration and heat treatment

    Vacuum de-aeration to protect aroma and vitamins, then flash pasteurisation for acid juices or UHT for low-acid products, depending on pH, product and pack.

  4. 04

    Filling

    PET, glass or aseptic carton; hot-fill or cold aseptic filling.

  5. 05

    Capping and labelling

    Torque, fill-level and coding checks.

  6. 06

    Palletising and dispatch

    End of line, stock management and batch release.

Bottles of fruit juice on a conveyor after capping

The challenges we see

  • Low OEE on the filling line
  • Long format changes and cleaning times
  • Product losses at start-up and changeovers
  • Microbiological stability and shelf life

How we help

  • Investment study: new line, new format or extension
  • OEE measurement, SMED on format changes, standard work
  • Validation of pasteurisation schedules and CIP cleaning
  • HACCP, ISO 22000 and customer-audit readiness
  • Preventive maintenance of fillers and end-of-line equipment

Standards and frameworks

  • Moroccan law 28-07 and ONSSA
  • HACCP
  • ISO 22000 / FSSC 22000
  • AIJN Code of Practice
  • Labelling and consumer-information rules

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