Export To Bulgaria Vial Filling Capping Line for Nasal Sprays, Throat Sprays, And Syrups.

Building a Benchmark Pharmaceutical Packaging Line in Bulgaria Through Excellence in Integration

Facing the dual demands of global supply chain dynamics and stringent pharmaceutical standards, a renowned Bulgarian pharmaceutical company presented us with a clear challenge: to create a fully automated, highly reliable, and perfectly tailored complete bottling line for their specific packaging needs. This line required a comprehensive process covering CIP cleaning, bottle unscrambling & filling and capping, labeling, cartoning, checkweighing, and information traceability coding, ensuring the efficient and compliant packaging of their syrup and spray products.

As a professional packaging line systems integrator, our core mission extends beyond supplying individual machines. We provide a one-stop service for production line creation, encompassing solution design, technical integration, manufacturing oversight, and complete line linkage testing. We firmly believe that successful integration starts with a precise understanding of client needs and rigorous technical implementation.

Phase 1: Precise Definition, Technology First

At the project's inception, we engaged in in-depth technical discussions with the client. Based on physical samples of the syrup bottle and two types of spray bottles, we jointly refined and confirmed the technical parameters for each stage, resulting in a detailed Technical File For The Bottle Filling Packing Line. This document became the cornerstone of the entire project, specifying:

• Product Compatibility: Exact bottle dimensions (e.g., syrup bottle: height 110mm, diameter 48mm; spray bottle: height 73mm, diameter 36mm), cap specifications, and the required dual mold changeover solutions.

• Process Requirements: Heating and stirring functions for the filler, a CIP hot water cleaning system (50L, removable), automatic measuring cup capping for syrup bottles, and the application of three Videojet inkjet printers for coding on bottle caps, labels, and carton ends respectively.

• Control & Integration Standards: Key line equipment (filler, cartoner) utilizing Siemens PLCs and touchscreen interfaces, with unified Ethernet ports and Modbus TCP communication protocol, laying the groundwork for intelligent linkage and data exchange.

• Output Goals: Cartoning speed, sealing type (tuck-in), and finished product collection methods.

  
  

Phase 2: Task Decomposition, Collaborative Manufacturing

To ensure technical requirements were accurately communicated to each manufacturing unit, we decomposed the overall plan into specific, actionable production task orders. These were issued to respective suppliers for the unscrambler-filler-capper (Yiya), cartoner (Gaoshang), checkweigher (Shigan), CIP system (Chuangbang), etc. Each task order included:

• Core Parameters: Equipment model, power requirements (e.g., 3-phase 380V or single-phase 220V), CE marking for export to Bulgaria, and delivery timelines.

• Specific Technical Requirements: For instance, the filler needed two sets of molds and air-cleaning functionality; the cartoner required an integrated leaflet folder and reserved interfaces for coders; the checkweigher needed ±0.1g accuracy and a rejection station.

• Unified Delivery Standards: All equipment was required to feature Hunan Dage-branded touchscreen interfaces, nameplates, and manuals. A detailed photo and video archiving process (covering run tests, electrical cabinet, nameplate, packaging) was mandated pre-shipment to ensure controllable and visible factory quality.

  
  

Phase 3: Rigorous Pre-Acceptance & Integrated Commissioning

Upon completion, the equipment was not shipped directly but gathered at our integration testing center. Here, we conducted strict Factory Acceptance Testing (FAT) and full-line linkage debugging, simulating actual conditions in the client's facility. We verified each item against the initial Technical File and Production Task Orders, generating a detailed Inspection Report - Rectification List.

This phase was crucial for ensuring both "individual machine stability" and "full-line smoothness." For example, debugging revealed the high sensitivity of the capping station to the straightness of spray bottle straws and the impact of carton orientation on the conveyor on final coding quality. Addressing these issues, we not only pushed equipment suppliers for mechanical and programming optimizations (e.g., adjusting capping guide mechanisms, optimizing rejection logic, adding fault alarm lights) but also proactively communicated with the client. We clarified the decisive impact of primary packaging material quality (e.g., straw rigidity, spray tube fit) on operational stability, assisting the client in improving material quality from the source.

Phase 4: Delivering Value, Exceeding Expectations

Through deep technical integration upfront, standardized manufacturing control mid-stream, and uncompromising integration testing and rectification at the final stage, this line destined for Bulgaria ultimately met the client's expectations. It is more than a simple series of connected machines; it is a complete, fully validated solution highly suited to their product characteristics, boasting stable production capacity and excellent maintainability.

We delivered our client peace of mind regarding their future production efficiency and product quality. This project reaffirms our core philosophy: true systems integration lies in solidifying every detail in technical documentation, verifying it on the test floor, and ultimately achieving (excellence) on the client's production site.

View videos of the production line system integration and acceptance testing.

Hunan GRAND Packing Machine

Ava Duan

Mobile/Wechat/Whatsapp: 0086-13706885851

Email: sales@grand-packing.com