Next‑Gen Combi‑Block Solutions for Liquid Packaging: From Blowing to Palletizing in Smart Beverage Lines

The Rise of Combi‑Block Systems in Beverage Packaging

Combi‑block machines—blowing, filling, capping (and sometimes labeling) merged into a single machine block—are transforming beverage lines. Instead of separate units with conveyors between each stage, combi‑block setups offer:

• Compact footprint

• Reduced air‑blowing and conveyors

• Lower labor and maintenance requirements

• Seamless integration from raw preforms to sealed bottles water

Technologies like Newamstar’s BLFC Starbloc and Tech‑Long’s ultra‑high‑speed combi‑block systems offer up to 60,000 BPH and integrate labeling modules for even greater automation and flexibility.

How Combi‑Block Lines Transform Liquid Packaging

Every Stage in One Block

• Blowing: Preforms are sterilized (optional), blown into PET bottles.

• Filling: Liquid (juice, water, carbonated beverage, etc.) is filled in aseptic or cold conditions.

• Capping: Sealing process integrated into the same block.

• Labeling (optional): Some combi‑blocks include inline labeling or wrap-around systems.

This eliminates conveyor delays and drastically reduces footprint.

Optimizing Efficiencies in Smart Beverage Lines

Energy & Cost Savings

By merging blowing, filling, capping, and labeling, combi‑blocks eliminate intermediate conveyors and buffer zones. That means:

• Lower compressed air use (no separate air‑drying)

• Less motor power required

• Reduced floor space

• Up to one operator can oversee multiple stations

High Throughput with Minimal Manual Intervention

Modern systems support up to 72,000 BPH with synchronized robotic handling, seamless sterilization, and fully integrated labeling and packaging.

Case Studies of Leading Edge Production Lines

Newamstar & Tech‑Long Implementations

• Newamstar installed lines for Tsingtao Brewery and other major beverage producers. These lines support PET bottle blowing, filling, capping, and labeling in one integrated solution.

• Tech‑Long’s 72,000 BPH combi‑block solution recently earned national recognition for innovation and performance.

Real‑World Benefits

• 30–40% energy savings vs traditional BFC+labeling lines

• Reduced labor needs (some lines run with one technician)

• Greater reliability and uptime thanks to integrated PLC and robotics

Key Technology Components in Combi‑Block Lines

PLC Control & Robot Stackers

• Siemens or equivalent PLCs manage real‑time coordination.

• Robotic arms handle launching, orientation, sterilization, and palletizing with minimal manual

Sterile Processing & Label Control

• Ionized air or H₂O₂ sterilization for bottle surfaces

• UV lamp and rinsing systems for cap feeding hygiene

• Optional hot‑fill or aseptic labeling modules for sensitive products

Conveyors, Wrappers & Palletizers

• Integrated bottle conveyors, robot palletizers, rotary-arm wrappers, and wrap-around cartons form downstream automation.

• Intelligent logistics solutions (AGV, RGV, WMS) enable smart warehouse integration.

Industrial Applications & Flexibility

Combi‑blocks support:

• Mineral water, still water, spring water

• Carbonated soft drinks

• Fruit juices, iced tea, energy drinks

• Coffee beverages, milk drinks, alcohol packaging

• Daily chemical liquids and edible oils

Speed, hygiene, and flexibility make these lines ideal for evolving beverage portfolios.

Overcoming Common Production Challenges

Maintaining Sterility

• Inline sterilization modes ensure full elimination of microbial risks.

• Enclosed zones with HEPA filtration or H₂O₂ rinsing maintain aseptic bottling.

Handling Speed vs Hygiene

• Dual robots for synchronized cap and bottle flow

• PLC‑based failsafe logic to prevent cross‑contamination or alignment errors

Modular Adaptation

• Quick retooling from CSD to water lines

• Adjustable neck and cap sizes for product changes with minimal downtime

Future-Ready Automation Trends

Higher Speeds with Smarter AI

• Predictive maintenance dashboards

• Real-time fill-level inspection and cap torque detection

• AI‑based control for fault detection and seamless changeovers

Hybrid Logistics & WMS Integration

• AGV or rail‑guided vehicles (RGV) link the combi‑block to automated warehouses and palletizers.

Flexible Manufacturing

• Lines capable of both PET and HDPE bottle processing

• Seamless transition between still and carbonated lines via smart software

Designing Your Next‑Gen Liquid Packaging Line

How Leonwholesale Can Help

We provide turnkey combi‑block line solutions tailored to your beverage profile:

• Blowing–Filling–Capping combo with optional labeling

• Sterile modules, conveyors, wrappers, palletizers

• PLC and HMI controls for scalable automation

• Intelligent logistics and warehouse integration

Consultation & Technical Support

• Full-site planning, layout optimization, and cost projections

• Training, commissioning, and 24/7 global service

• Remote diagnostics and project upgrades

Contact & Next Steps

Curious about how a combi‑block system can revolutionize your production?

📞 WhatsApp: +86 181 3677 3114
📧 Email: leonxu0317@gmail.com

Let's tailor your next generation beverage line—from blowing to palletizing.

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