In 2017, Tuyao delivered a complete 12000BPH bottled water production line to a first-time beverage investor in Addis Ababa, Ethiopia, as a full turnkey project built entirely from scratch. Covering plant layout planning, water treatment, bottle blowing, filling, labeling and end packaging, the fully automatic line was custom-engineered to match local raw water conditions, the client’s new workshop structure, and market demand for 600ml PET bottled drinking water. Our engineering team supported the project from early planning through to full production, helping the client launch their bottled water brand and capture share in Ethiopia’s fast-growing packaged drinking water market.
Recognizing the rapid growth in consumer demand for safe packaged water across Ethiopian cities, the client planned to build a new modern bottling plant from the ground up, but lacked hands-on experience in plant design, equipment selection and production operation. After evaluating suppliers from China and Europe, they chose Tuyao for our end-to-end turnkey capability, proven track record in African markets and full-cycle technical support.
As a greenfield project with no existing production foundation, the client faced four core challenges before launch:
1. Zero-experience plant planning — The client had no professional knowledge of workshop layout, utility matching or process flow design, and could not independently complete plant planning and equipment specification.
2. Local raw water quality constraints — The local water source had high turbidity and fluctuating mineral content, requiring a customized water treatment system to meet national drinking water standards.
3. Untrained operations team — The client’s team had no prior experience with high-speed automatic filling equipment, requiring a full, zero-based training system for stable long-term operation.
4. Cross-phase project coordination — Without a single point of accountability for civil works, equipment delivery and commissioning, the project faced high risk of delays and mismatched on-site conditions.
Tuyao provided a full end-to-end turnkey solution built from the ground up, tailored to the Ethiopian market and the client’s greenfield project needs. Our engineering team engaged at the pre-construction stage, conducting a full assessment of the client’s planned workshop dimensions, power supply capacity, raw water quality and 600ml bottle specifications, then delivered an optimized full-plant CAD layout and line configuration that maximizes space efficiency and reserves room for future capacity expansion.
· Integrated rotary washing-filling-capping monobloc design to minimize floor space and contamination risk
· Customized multi-stage RO water treatment system engineered specifically for local raw water quality
· Full SUS304 stainless steel construction for all product-contact parts, fully compliant with food safety standards
· PLC control system with intuitive touchscreen interface, designed for easy operation by first-time users
· Modular line design with reserved upgrade interfaces to support future capacity growth and bottle format changes
At the pre-construction stage, our engineering team provided the client with detailed guidance on civil works, utility point reservation and equipment delivery requirements, ensuring seamless alignment between construction progress and equipment manufacturing.
The entire line was manufactured and fully performance-tested at our Zhangjiagang facility within 80 days. After the client completed the Factory Acceptance Test (FAT) via live video inspection, the equipment was shipped to Djibouti port and transported to the client’s plant in Addis Ababa.
Our senior installation engineer was dispatched on site to oversee:
· Equipment positioning, assembly and pipeline connection according to the pre-approved CAD layout
· Full line commissioning and performance verification
· Zero-based two-tier training for operators and technicians, covering daily operation, routine maintenance and fault diagnosis with hands-on guidance
· Site Acceptance Test (SAT) confirming 12000BPH stable output with 99.9% filling accuracy
After six months of continuous production, the greenfield 12000BPH water filling line has delivered outstanding results:
· Stable output reaching the rated 12000 bottles per hour for 600ml PET bottles, fully supporting the client’s initial market launch and distribution
· Filling accuracy above 99.9%, significantly reducing raw material waste and controlling production costs
· Consistent treated water quality fully meeting Ethiopian national drinking water standards, ensuring stable product quality
· The client’s team has fully mastered independent operation and routine maintenance; paired with remote IoT diagnostic support, the line maintains a very low failure rate
“As a first-time bottled water manufacturer, our biggest concern was making costly mistakes building everything from scratch. The Tuyao team guided us professionally through every step — from plant construction and utility setup to equipment operation and troubleshooting. It saved us enormous time and hassle. The line is running steadily now, and our 600ml products have already entered multiple local distribution channels, which exceeded our expectations.” — Plant Manager, Client Company
Whether you are planning a brand-new bottling plant or upgrading an existing production line, Tuyao provides customized turnkey water filling solutions from 2000BPH to 36000BPH for clients worldwide. Share your bottle specifications, capacity targets and site conditions with us, and our engineering team will prepare a tailored line layout and transparent quotation for your project.
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