In a modern factory on the outskirts of Lima, the capital of Peru, a brand-new water bottling production line is operating smoothly. Bottles of clear drinking water line up neatly, as robotic arms precisely seal two different cap designs—standard caps and sports caps—onto the respective products. This intelligent production line, custom-designed by Xinmao's factory in China and transported across the Pacific Ocean, is helping this Peruvian drinking water company achieve a qualitative leap in production capacity.
Client Needs: The Challenge of Dual-Function Machines
Early last year, Xinmao's factory received a special inquiry from a Peruvian drinking water producer. This company, which holds a significant share of the Peruvian market, faced the challenge of expanding its product line: they needed to produce both traditional screw-cap bottled water and launch push-cap sports cap products suitable for athletes. The marketing department's requirements were clear—both products needed to be produced, but production space and budget were limited, and they hoped to find a production line capable of bottling both types of caps.
“We need a production line that can quickly switch between standard cap and motion cap production modes without replacing major components,”the client emphasized in a video conference.“The switchover time must be controlled within 30 minutes, and it cannot affect filling accuracy or hygiene standards.”
This is a classic example of the“have your cake and eat it too”industrial challenge. Standard screw caps and motion caps differ significantly in structure, sealing principle, and encapsulation process: standard caps mostly use threaded tightening, while motion caps typically require a press-type sealing mechanism and a special channel design. Traditional solutions involve configuring two separate production lines or purchasing expensive full-featured equipment, but both of these solutions exceeded the client's budget and space constraints.
Xinmao's Solution: The Perfect Answer Through Innovative Design
Faced with this technical challenge, Xinmao's engineering team did not back down. After two weeks of technical discussions, they proposed an innovative modular design solution.
“We adopted a‘basic platform + replaceable modules’design concept,”explained Wang, the chief engineer of the project at Xinmao.“The core filling, sterilization, and conveying systems of the production line remain unchanged, but in the capping stage, we designed an intelligent switching system. Operators only need to replace the capping module and adjust a few parameters to switch between ordinary cap and moving cap modes.”
The challenge of this solution lies in ensuring that two completely different capping processes achieve the same precision and efficiency on the same equipment. The Xinmao team creatively developed the following key technologies:
Adaptive Capping Head System: Employing quickly replaceable capping head modules equipped with intelligent sensors, it automatically identifies the currently installed cap type and adjusts pressure, rotation speed, and sealing parameters.
Dual-Rail Cap Supply System: Designed with two independent cap supply tracks and temporary storage compartments, it allows for the supply of different caps through simple mechanical switching, avoiding cross-contamination and confusion.
Intelligent Control System: Developed specialized control software that stores all parameters for both production modes. Switching requires only a one-click selection, and the system automatically adjusts the operating parameters of all relevant equipment.
Sanitary Quick-Connect Device: All replaceable modules feature a sanitary quick-connect design, ensuring no contamination risk is introduced during replacement while significantly reducing changeover time.
After three months of intensive design, manufacturing, and testing, Xinmao's factory not only completed equipment production on time but also reduced the changeover time from the customer's required 30 minutes to an astonishing 15 minutes, achieving a filling accuracy of±0.5 ml, far exceeding industry standards.
Transoceanic Delivery and Service: After the equipment was manufactured, the next challenge was safely transporting this 20-ton precision equipment to Peru and successfully installing it. Xinmao's factory assembled a professional team including engineers, installation technicians, and Spanish translators, and developed a meticulous transportation and installation plan.
"We used specialized shock-resistant packaging, providing double protection for critical components," said Manager Li, responsible for international delivery. "We also communicated with the Peruvian customer in advance, guiding them in preparing the installation site and infrastructure to ensure installation could begin immediately upon arrival."
This year, the equipment successfully arrived at the Port of Lima. Xinmao's technical team immediately flew to Peru to conduct a two-week installation and commissioning operation. They not only completed the equipment installation but also provided comprehensive training for the client's operators and maintenance personnel, ensuring the local team could skillfully operate and maintain the equipment.
Client Feedback: Satisfaction Exceeding Expectations
Two months after the equipment went into operation, the client reported excellent news—the new production line not only fully met their production needs but also brought unexpected benefits.
“The performance of this production line exceeded our expectations,”the feedback email stated.“The switch between regular caps and sports caps takes only 15 minutes, faster than we originally anticipated. More importantly, the equipment's stability and filling accuracy are outstanding, and our product qualification rate has increased from 98.2% to 99.5%.”
The client added,“Xinmao's equipment also has significant energy-saving effects, reducing energy consumption by approximately 18% compared to other solutions we considered. Moreover, their intelligent control system is very user-friendly, and our operators can use it proficiently after a short training period.”
With the new production line in operation, the client successfully launched its sports cap product series, quickly gaining a foothold in the Peruvian sports drink market. The company expects the new production line to help them increase capacity by 40% and reduce production costs by 15% within the next two years.
Xinmao's Commitment: Making "Made in China" Shine Globally
This success story not only showcases Xinmao's technological strength but also vividly illustrates the transformation of "Made in China" to "Intelligent Manufacturing in China." The General Manager of Xinmao's factory, summarizing the project, stated, "Our goal is not simply to sell equipment, but to provide customers with complete solutions. The satisfaction of our Peruvian customers once again proves that through technological innovation and lean manufacturing, Chinese equipment can fully meet the most demanding requirements of the international market."
As the global market continues to demand greater flexibility and intelligence in production equipment, Xinmao's factory will continue to increase its R&D investment, applying more innovative technologies to the filling equipment field to create value for global customers.
From the Peruvian Andes to the other side of the Pacific Ocean, this intelligent filling production line not only connects the industrial production of the two countries but also witnesses the bridge of trust built between "Made in China" and international customers based on technological innovation and quality assurance. In the era of globalization and intelligent manufacturing, such cooperative stories will continue to unfold.
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