First, the newly made bottles need to be put in a single line ready to be labeled. This 30m long conveyor belt moves at variable speeds so, if there is any blockage in the filling section the bottles can be slowed down here. Every hour one roll of labels will go on to 16,000 buckles. During this stage, commercial labels are attached to the plastic containers as they pass through the labeling machine. Each bottle is spun as the label is glued on; a brush smooths the label removing any statical electricity. But before any of these bottles can be filled their caps need to be made.
In this area, the caps are made from the same material to the milk bottles. Again, the pellets first caught into a blending machine where they are mixed with dies. Second, the mix is heated to 230 degrees Celsius before being pushed into the molding machine. With 32 cavities in each machine, they can produce over17,000 caps an hour. When a box of caps is finished it makes its way into the filing area so, each cap can be attached to a bottle.
For the very first time the caps, the milk, and the two-liter bottles head down to the filling line. Pipes run from the milk processing room where the milk was pasteurized and homogenized directly into the fillable. The chilled fresh milk will be held here until the bottles come through. As each bottle approaches, it first needs to be marked with production and expiry dates. A pressurized ink droplets are deflected onto the outside of each bottle. Next, it’s time to put the milk in, as each bottle moves under the fillable a mechanical lifter connects it to nozzle which starts the flow of the milk. The filling and selling operation are fully automated, 60 bottles are filled in one rotation and they are immediately caped. Then the complete bottles move past inspection, those with defective capes are removed manually. Before the bottles can be packed, they pass through a water shower to ensure that any milk dripped onto the bottle is cleaned off.
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