In January 2024, our company partnered with a renowned Iranian beverage manufacturer, successfully delivering a fully automated aseptic carton filling production line for juice. This system includes aseptic filling machines, labelers, film shrink wrapping machines, and carton packaging machines, with a designed production capacity of 7,500 boxes per hour. The project has now become a benchmark case for high-end beverage production equipment in the Middle East region.
Aseptic carton filling machine: Using German imported sterile valve group and ultra-high temperature instantaneous sterilization (UHT) system, it can achieve filling of 200-1000ml multi specification paper boxes; Adopting a fully automatic isolator system, with an easy to clean internal design to prevent external pollution, and a sealing accuracy of 99.99% under sterile air protection;
High speed tube sticking machine: Equipped with a visual positioning system, the tube sticking speed is synchronized with the filling machine (7500 boxes/hour), and the tube sticking deviation is ≤ 0.5mm;
Film shrink packaging machine: Using PE environmentally friendly film, intelligent control of heat shrink temperature, packaging compactness increased by 40%, and energy consumption reduced by 25%;
Fully automatic carton packaging machine: Integrated robot palletizing system, the entire process of carton forming, packing, sealing, and palletizing is automated, reducing labor by 80%.
·Sterility guarantee: Through SIP (in-line sterilization) and CIP (in-line cleaning) systems, an aseptic environment is achieved inside the equipment, maintaining the nutritional value and freshness of the juice, and reducing the risk of spoilage by 15%;
·Intelligent control: Equipped with an industrial internet platform, it can monitor real-time operating parameters of the equipment (such as filling temperature, sealing pressure, packaging speed), and automatically alarms in case of abnormal situations, with the fault handling response time shortened to 15 minutes.
2. Product quality upgrade: The aseptic process retains more than 90% of the nutritional components of the juice (such as a 35% increase in vitamin C retention rate), enhances the product's premium ability, and increases the terminal selling price by 15%;
3. Significant cost reduction: After automation transformation, the packaging error rate has been reduced to 0.5%, labor costs have been reduced by 60%, and annual cost savings of about 1.2 million US dollars have been achieved;
4. Accelerated market expansion: with the advantage of long shelf life, customers successfully entered Iraq, Türkiye and other surrounding markets, and the export volume increased by 80% year on year.
Customer Review
"Union Machinery's production line not only solved our production capacity issues, but also ensured that the product quality reached international standards. Now our juice can stay on the shelves for an entire year, and the export orders are coming in continuously. This is an outcome that we couldn't have imagined before our cooperation!"
— Mr. Ali, Production Director of the Iranian Customer
· Global Expertise: 11+ years in food machinery, serving 50+ countries.
· Certifications: ISO9001 and CE compliant.
· Custom Solutions: Full-service support, including plant layout optimization.
· Support: 24/7 technical assistance, spare parts availability, 1-year warranty.
Take action! Make your business the next success story
If you also face problems such as insufficient production capacity, outdated aseptic technology, and low automation level, Union Machinery can provide a full process service from production line design, equipment manufacturing, installation and commissioning to after-sales training. Contact us immediately for exclusive customized solutions!
Union Machinery， A global leader in food packaging, committed to enhancing customer competitiveness through innovative machinery. Complete export certification and 100% on-time project delivery rate.
Union Machinery —— Make every bottle of juice your own quality signature!
Client Background and Pain Points
The Iranian client is a leading local producer of fruit juice beverages, with products covering multiple countries and regions. With the rapid growth of market demand, the existing production lines are no longer able to meet the requirements of efficient, sterile, and large-scale production. The customer urgently needs an integrated solution with the following capabilities:- Meet the high output requirement of 7,500 cases per hour;
- Fully comply with international aseptic production standards to avoid product contamination risks;
- Achieve full automation from filling to cartoning, reducing labor costs;
- Adapt to various size cardboard packaging and flexibly adjust production mode;
- Stable and reliable equipment, reducing downtime due to malfunctions.
Solution: Complete set of intelligent equipment, seamlessly integrated with high efficiency and sterility
In response to customer demands, Union Machinery, leveraging its over 10 years of experience in food machinery research and development, offers an integrated solution of "sterile filling + intelligent packaging". The core equipment includes:Aseptic carton filling machine: Using German imported sterile valve group and ultra-high temperature instantaneous sterilization (UHT) system, it can achieve filling of 200-1000ml multi specification paper boxes; Adopting a fully automatic isolator system, with an easy to clean internal design to prevent external pollution, and a sealing accuracy of 99.99% under sterile air protection;
High speed tube sticking machine: Equipped with a visual positioning system, the tube sticking speed is synchronized with the filling machine (7500 boxes/hour), and the tube sticking deviation is ≤ 0.5mm;
Film shrink packaging machine: Using PE environmentally friendly film, intelligent control of heat shrink temperature, packaging compactness increased by 40%, and energy consumption reduced by 25%;
Fully automatic carton packaging machine: Integrated robot palletizing system, the entire process of carton forming, packing, sealing, and palletizing is automated, reducing labor by 80%.
Technical Highlights:
·Capacity increase: The production line speed reaches 7,500 boxes/hour, which is 140% higher than the original equipment of the customers;·Sterility guarantee: Through SIP (in-line sterilization) and CIP (in-line cleaning) systems, an aseptic environment is achieved inside the equipment, maintaining the nutritional value and freshness of the juice, and reducing the risk of spoilage by 15%;
·Intelligent control: Equipped with an industrial internet platform, it can monitor real-time operating parameters of the equipment (such as filling temperature, sealing pressure, packaging speed), and automatically alarms in case of abnormal situations, with the fault handling response time shortened to 15 minutes.
Project achievement: 100% customer satisfaction, significant economic benefits
1. Double breakthrough in production capacity and efficiency: After the production line is put into operation, the daily production capacity of customers has increased to 160000 boxes, the peak season order delivery rate has reached 100%, and the market share has increased from 12% to 18%;2. Product quality upgrade: The aseptic process retains more than 90% of the nutritional components of the juice (such as a 35% increase in vitamin C retention rate), enhances the product's premium ability, and increases the terminal selling price by 15%;
3. Significant cost reduction: After automation transformation, the packaging error rate has been reduced to 0.5%, labor costs have been reduced by 60%, and annual cost savings of about 1.2 million US dollars have been achieved;
4. Accelerated market expansion: with the advantage of long shelf life, customers successfully entered Iraq, Türkiye and other surrounding markets, and the export volume increased by 80% year on year.
Customer Review
"Union Machinery's production line not only solved our production capacity issues, but also ensured that the product quality reached international standards. Now our juice can stay on the shelves for an entire year, and the export orders are coming in continuously. This is an outcome that we couldn't have imagined before our cooperation!"
— Mr. Ali, Production Director of the Iranian Customer
Why Choose Union Machinery?
· Expert Team: End-to-end engineering support from design to commissioning.· Global Expertise: 11+ years in food machinery, serving 50+ countries.
· Certifications: ISO9001 and CE compliant.
· Custom Solutions: Full-service support, including plant layout optimization.
· Support: 24/7 technical assistance, spare parts availability, 1-year warranty.
Take action! Make your business the next success story
If you also face problems such as insufficient production capacity, outdated aseptic technology, and low automation level, Union Machinery can provide a full process service from production line design, equipment manufacturing, installation and commissioning to after-sales training. Contact us immediately for exclusive customized solutions!
Union Machinery， A global leader in food packaging, committed to enhancing customer competitiveness through innovative machinery. Complete export certification and 100% on-time project delivery rate.
Union Machinery —— Make every bottle of juice your own quality signature!
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