Turnkey Juice & Beverage Production Solutions | From Processing to Final Packaging

TUYAO provides comprehensive solutions for fruit juice, tea drinks, and energy drinks. We support every stage from raw material processing to high-speed hot filling and final packaging.

SOLUTION OVERVIEW

A Complete Juice Production Ecosystem from One Manufacturer

Producing quality juice requires precise temperature control and strict hygienic standards. TUYAO’s juice filling lines integrate fruit processing, blending, UHT sterilization, and precision hot filling to ensure product safety and optimal taste.

Targeted Solutions for Every Beverage Type:

Clear Juice & Tea Drinks: High-speed hot filling solutions (85-92°C) for smooth, premium beverages.	Pulp & Juice with Bits: Specialized 4-in-1 filling systems for juice containing fruit sacs, pulp, or fiber.

PROCESS FLOW

Professional Layout Planning for Complex Beverage Projects

We provide customized CAD production line layouts that include both the Processing System (Mixing/Sterilization) and the Packaging System to optimize your workshop space and energy efficiency.

CAPACITY PLANNING

Scalable Solutions for Your Business Growth

Whether you are starting with a 3,000BPH boutique facility or a 36,000 BPH industrial plant, TUYAO recommends the optimal configuration for your budget and target output.

LINE EQUIPMENT

Core Equipment Included in a Juice Filling Line

Water Treatment System

Our water treatment systems are fully custom-engineered to your raw water conditions. After reviewing your water analysis report, we design a tailored solution combining pre-filtration, reverse osmosis (RO), ultrafiltration (UF) and ozone/UV sterilization for deep purification — effectively removing contaminants, reducing hardness and ensuring compliance with drinking water standards.

Juice Processing System

We design custom beverage processing systems tailored to your product requirements, built for pre-filling preparation of juice, carbonated drinks and other beverages. Core modules cover fruit extraction, sugar dissolving, blending, ingredient dosing, homogenization, degassing, UHT sterilization, HFSC storage, hot water supply and CIP systems.

All systems feature premium sanitary valve fittings, precision control instruments and high-quality electrical components, with scalable capacities from 1T to 100T based on your production needs.

Bottle Blowing System

Our PET bottle blow molding machines support fully custom bottle shapes and serve a wide range of beverage applications. We offer two configurations to fit different production scales:

Semi-automatic blow molder: Manual operation with low upfront investment, ideal for small-batch production and startup plants.

Automatic blow molder: High-level automation for medium to high-speed production lines, ensuring stable output with reduced labor demand.

Automatic models produce PET bottles from 100ml to 2,000ml, commonly used for water, soda and cola bottles. All bottle profiles can be customized to your exact design requirements.

Juice Filling Machine

This 3-in-1 rinsing-filling-capping monobloc leverages advanced global filling technology, engineered for fruit juice, tea, energy drinks and other non-carbonated beverages. It integrates mechanical, electrical and pneumatic control systems, fitted with world-renowned core components and a PLC touchscreen HMI for intuitive operation.

Key highlights include stable filling accuracy, precise liquid level control, reliable capping, variable frequency speed adjustment and minimal product waste. Stable output ranges from 3,000 to 36,000 BPH for PET bottles.

Labeling Machine

We deliver customized final packaging solutions aligned with your needs and market demand, with three mainstream label options for bottle — PVC shrink sleeve, OPP hot-melt glue and self-adhesive labels — each paired with dedicated labeling equipment. As refined label design effectively boosts brand recognition and market appeal, we recommend referencing local mainstream products when making your selection.

Bottle Packging System

Individual bottled water requires secondary packaging to withstand long-distance transportation and storage. We provide a range of end-of-line packaging solutions, including PE shrink wrapping, carton packing and film-with-tray packaging, each paired with purpose-built equipment.

PE shrink film packaging is the most common choice for bottled water plants due to its low material cost, while carton packaging is typically selected for premium bottled water or glass bottle lines.

FAQ

Frequently Asked Questions About Juice Filling Lines

1. What is included in a complete juice filling line?

A complete juice filling line can include fruit juice processing, blending, homogenizing, degassing, UHT or plate sterilization, hot filling, capping, bottle cooling, labeling, coding, and final packaging. TUYAO designs the line based on your beverage type, bottle format, shelf-life target, and production capacity.

2. What is hot filling and why is it used for juice production?

Hot filling is a process where juice is filled into bottles at a high temperature, commonly around 85-92°C, to help control microorganisms and improve shelf stability. It is widely used for fruit juice, tea drinks, and high-acid beverages because it supports safe production while maintaining flavor and product quality.

3. Can TUYAO juice filling lines handle pulp or fruit particles?

Yes. TUYAO can configure specialized filling systems for juice containing pulp, fruit sacs, fiber, or small particles. For pulp juice, the filling valve structure, pipe diameter, tank design, and cleaning system need to be adapted to prevent blockage and maintain consistent filling performance.

4. What capacity range can TUYAO provide for juice production lines?

TUYAO juice filling lines can be customized from smaller production capacities such as around 3,000 BPH to larger industrial lines around 36,000 BPH or higher depending on bottle size and process scope. The final capacity depends on the processing system, filling machine, bottle format, and packaging method.

5. Why is a bottle cooling tunnel needed after hot filling?

After hot filling, bottles need to be cooled gradually to protect bottle shape, preserve product flavor, and prepare the surface for labeling and packing. A cooling tunnel helps reduce product temperature in a controlled way and prevents deformation or label quality issues caused by excessi+ve heat.

6. Can TUYAO provide both processing and packaging equipment for juice lines?

Yes. TUYAO can provide an integrated solution covering the processing system and packaging system. This can include blending tanks, sterilization equipment, hot filling monoblock, cooling tunnel, labeling machine, coding system, shrink wrapper, carton packer, and conveyors.

7. How should I choose a juice filling line for my beverage project?

To choose the right juice filling line, you need to confirm the beverage type, whether it contains pulp, the required shelf life, bottle material, bottle size, target capacity, and factory layout. TUYAO engineers can use this information to recommend the filling method, sterilization process, and packaging configuration.