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Maker - Product Challenge

Products

Technologies

About us

Changemakers

Let's make energy drinks

Blending

Bottling

Canning

Homogenization

Pasteurizing

The US Brewers Association estimates that the average American lives within 15 kilometers of a craft brewery. Although small in scale, these breweries are big on quality and rely on advanced craft beer making equipment to perfect their unique methods. Beer-making has a proud history, and craft brewers dig deep into the tradition to bring innovative alternatives to the market.

Craft beer

As simple as its own ingredients, the grain-hops-yeast trifecta along with water are the big four ingredients for making beer. The beer-making process is known as brewing and involves several steps like milling, mashing, lautering, boiling, and fermentation.

Beer

Energy drinks have come a long way since the tangy, fizzy products popularized in the 1990s. The beverage category today is responding to wellness trends by reducing sugars and adding vitamins. But the basis for making energy drinks remains caffeine anhydrous, which acts as a stimulant. Unique recipes are finished with an array of ingredients, from herbal extracts to taurine to flavorings. Pasteurize the water-based mixture to eliminate microbial growth and extend the drink’s shelf-life.

Energy drinks

Mpac Group is an industry leader in packaging automation, cartoning, and case-packing technologies.

Small footprint (6.5’ L x 5.8’ W x 6’ H)

Corrosion-resistant frame and components

Quick changeover between formats

Accommodates different can profiles and packaging formats

Caster wheels allow portability

Cans have many advantages over bottles when it comes to packing, for example, your craft beer. Having a flexible automatic cartoning system for your different beer types and cases will significantly improve your process efficiency. Smaller scale manufacturers now also opt for an upgrade in their production line to efficiently erect, load and close their carton packaging.


<h2>Pack your craft beer cans into cartons automatically</h2>
The Switchback BRC-1, from Mpac Langen, is an automated carton packaging system for canned beverages such as beer, coffee, and energy drinks. The packing system has compact dimensions and is equipped with caster wheels for portability and leveling legs. A robotic arm gently handles the carton to open and close the packaging while a belted conveyor loads the cans via a pneumatic actuator. It can accommodate different can sizes, such as slim, sleek, or standard, and can pack them in 4, 6, 8, 9, or 12 formats with a maximum throughput of about 5 cartons per minute. The cartoner has a stainless steel frame and components for corrosion resistance and easy cleaning.

Horizontal Beverage Can Cartoner

Packaging

Food

Batch

Industrial canning is an important packaging step within the food processing industry for items such as beverages and tinned products. Automatic dosing and weighing systems portion out your product before distributing it into separate cans. A can seamer then folds the lid over the flange of the container, hermetically sealing the can. Some manufacturers opt for an additional plastic cap allowing consumers to re-close the can after the lid would have been peeled off.

Cartoning involves erecting a folded carton, filling it with the product, closing the flaps, or applying a lid and sealing with glue or adhesive tape. Choosing a cartoning solution involves, considering the type of primary packaging, the production volume, the size and count of the product in a carton, and the desired level of automation.

Cartoning

<span style="font-weight: 400">At last, you reached the final stage of processing your product - welcome to the packing world! Packing preserves and protects a product from damage, spoilage, and contamination while it makes its way from the production line to the consumer or further production. Depending on which industry your products belong to, the type of primary packaging equipment can change drastically. You need to pay careful attention to products with </span><span style="font-weight: 400">chemicals or hazardous substances since they can be potentially dangerous to human health. </span>

Packing

A beverage is any kind of liquid or drink, usually other than water, made for human consumption. Beverages are further classified into two categories: alcoholic beverages and non-alcoholic beverages. Alcoholic beverages refer to liquids that contain 1% to 75% of liquor and are produced by fermentation such as wine, beer, or distillation such as vodka, rum, tequila. Non-alcoholic beverages are drinks that don’t have any liquor such as tea, coffee, fruit juices, soft drinks, and carbonated beverages. They can be produced premix or postmix, depending on the setup of your production line.

Beverages

Our food chain starts in the soil, growing crops and livestock. But between the fields and the stores, there is a line of industrial food processing equipment. Processes may be as minimalistic as cleaning fruit and as complex as homogenizing milk alternatives made from pressed legumes. In each case, processing technology is an important link in the food production chain.

liquid

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Originally developed as medicinal remedies, soft drinks quickly burst into a whole new category of non-alcoholic beverages. To make a soft drink, simply dissolve one part syrup into five parts water. For extra punch, add carbon dioxide to turn the mixture into a fizzy drink.

Soft drinks

Pineapples, oranges, passion fruit, you name it. A fruit juice process begins with selecting and cleaning the raw material of your choice and goes through steps like extraction and a filtration machine until it reaches market shelves in bottles. Juice processing equipment varies according to the amount of water in the fruit.

Fruit juice

Comac Italia specializes in designing and manufacturing beverage bottling and packaging equipment, offering complete solutions for breweries, wineries, and beverage producers worldwide.

Automation and control functions enhance operational efficiency

Customizable configurations to suit specific customer requirements

Pilot plant available for testing and simulating non-standard products

Adjustable bottle and can feeding frequency for flexible cycle duration

Stainless steel design ensures durability and ease of maintenance

Efficient pasteurization is crucial for ensuring product safety and quality in the beverage industry, including beer, alcoholic and soft drinks, fruit juices, isotonic drinks, energy drinks, and ice teas. Achieving precise control over temperature and process timing is essential to avoid over-pasteurization and maintain product integrity.
<h2>Ensure precise temperature control and uniform pasteurization</h2>
The Tunnel Pasteurizer by Co.Mac is designed for the pasteurization of already packaged products like cans and bottles. This system features a robust stainless steel AISI 304 structure, which undergoes abrasive blasting and a protective coating for durability. It operates by transporting bottles and cans on a plastic chain through various sections encountering upper showers at different temperatures. Users can set the feed rate to adjust cycle duration via an operator panel. To conserve cooling water, the cycle is programmed with instrumentation that maintains constant water temperature in the tanks. The unit includes inside tanks feeding the upper showers, command and control instruments outside, automatic over-pasteurization prevention during conveyor stops, and easy-to-clean extractable double panel filters. The stainless steel electrical panel, complete with an operator interface, allows for real-time monitoring and control adjustments.

Tunnel pasteurizer for beverages

Process

A belt conveyor system uses pulleys or drums to keep an endless loop of conveying belts in continuous motion for material handling. Considerations for choosing a suitable conveyor belt system include the physical form of the product, processing requirements, and the desired speed and volume of transportation. Belt conveying systems find numerous applications in the food, pharmaceutical, and chemical industries such as filling and packaging operations. In the biomass industry, these systems are used for moving biomass feedstock to the boiler. In the mineral industry, conveying belts process and transport granular and crushed minerals. Conveyor belts are heavy-duty machinery that is used to move materials from one place to another. They are commonly used in factories, warehouses, and other industrial settings to move items such as boxes, containers, and other materials along a production line.

Conveyor belts

Your cooked foods are typically exposed to high heating conditions and could take a long time to drop to the right temperatures for further processing or packaging. Cooling tunnels consist of a series of blowers and exhaust hoods that rapidly extract the heat from your products as they travel on a conveyor belt.

Cooling tunnels

Continuous

Industrial

Pilot

Conveyor systems are used for moving materials from one location to another. Considerations for choosing a suitable industrial conveying system include the nature of the product, its physical state, the desired conveying rate, and sensitivity of the product to heat and mechanical shock. Conveying equipment is used in the food, pharmaceutical, chemical, biomass, and mineral industries to move materials around a warehouse as well as to transport bulk powders, granules, and grains for processing and filling. These types of systems are usually automated and there is a wide variety of solutions to choose when it comes to the type of conveyor. Types include screw, gravity, chain, roller and belt conveyors.

Conveying

Industrial cooling equipment varies according to the consistency and temperature conversion demands the material you are handling, but the process typically involves heat exchange treatment as your products are conveyed through a cooling chamber equipped with extraction fans or circulating water. Temperature control is a crucial aspect of your commercial production and cooling systems are applied to a range of industries.

Cooling

<span style="font-weight: 400">The heating process is a step of raising the temperature of food, pharma, cosmetics, and many other types of products. You may employ different heating solutions for this process, depending on the type of product you intend to manufacture. Selecting the appropriate heater machine for your product is quite important since various products require different ranges of temperatures and different ways of heat transfer using exchangers. Industrial heating equipment varies in two ways - the type of material it can process and the reaction you want to achieve.</span>

Heating

Complex processes call for continuous tracking and monitoring systems that help you to keep the manufacturing operation under control. The technology analyzes the components in the production phase for divergence in behavior or changes in conditions. Based on advanced software applications, monitoring platforms make sure that your products satisfy the quality criteria while they are being developed.

Monitoring

The Pasteurization process is the method of subjecting liquids to mild heat at a specific temperature and time, and quickly cooling them down again in order to destroy pathogens in your fermented or semi-fermented products. Thus, increasing the shelf life of the manufactured products. Untreated microorganisms may lead to diseases, spoilage, or unwanted fermentation. Most pasteurization equipment operate in a continuous method using plate heat exchangers to keep a uniform level of high efficiency sterilization.

Fruit

The winemaking process starts with harvesting and crushing grapes, goes through fermentation, ageing and finishes with packaging. Winemaking supplies vary according to the desired wine and the production or plant size.

Wine

Maintains beverage quality by regulating temperature

Easy cleaning and maintenance with accessible tank doors

Supports multiple beverage types and container formats

Available in different sizes to suit production needs

Reduces risk of microbial growth and structural issues

In beverage production, managing the temperature of packaged products is critical to ensuring quality and safety. Packaging beverages at either cold or hot temperatures can lead to microbial growth or structural integrity issues, making effective temperature control essential.
<h2>Efficiently regulate beverage temperature post-packaging</h2>
The heating and cooling tunnel from Co.Mac is designed to regulate the temperature of packaged beverages, bringing them to room temperature efficiently. Suitable for products like beer, wine, soft drinks, hard seltzers, ready-to-drink beverages, and energy drinks, it handles multiple container formats, including cans and glass bottles. The system features easy cleaning and maintenance, with each tank equipped with doors on one side and double panel filters that can be extracted from the pumps side. Available in sizes of 10 sqm, 25 sqm, and 36 sqm, the tunnels are capable of handling various production scales.

Heating and cooling tunnel for beverages

Your processed foods are passed through a spiral cooler to quickly freeze them down and maintain a uniform temperature between defrost stages. Products are loaded onto a coiled conveyor surrounded by evaporators that draw out the moisture from your items. Meanwhile, large flow fans circulate cool air  at a controlled temperature.

Spiral coolers

Mineral water is mother nature’s cocktail of dissolved solids. The concentration of essential chemicals in the water makes it an excellent source of nutrients and electrolytes. Although your bottled product retains most of the properties present at its natural condition, the water still needs some help before it can be safely consumed.

Mineral water

Alps Machine manufactures high-end beverage packing and filling solutions since 2011, including water and beverage fillers, labeling machines, packing machines, and water treatment systems

Consistent and efficient high-speed bottling

Automated PLC control for precise operations

Reduces bottle damage with advanced capping system

Easy to clean and maintain with stainless steel components

Accommodates various bottle sizes up to 2L

In large-scale beverage production, maintaining consistent quality and efficiency during the bottling process is crucial. Challenges like bottle integrity during washing, precise filling, and secure capping are common and can slow down operations.
<h2>Streamline washing, filling, and capping processes</h2>
The 10000BPH Automatic Carbonated Drink Filling System by Alps Machine integrates washing, filling, and capping functions in one automated unit. Designed for PET bottles ranging from 250ml to 2L, it boasts an advanced isobaric filling technology for stable and quick operations, ensuring production capacities of up to 10,000 bottles per hour. The system uses PLC control for precise and seamless automated runs. Stainless steel components and a high-precision filling nozzle ensure hygiene and minimal product loss. Noteworthy is its electromagnetic capping heads, which include a burden discharge function to minimize bottle damage. Suitable for carbonated drinks, soda water, and energy drinks, the machine's design allows easy adjustments for different bottle sizes and types, offering flexibility and efficiency for beverage manufacturers.

High-capacity carbonated drink filling system

Bottle capping solutions

Bottle filling equipment entails transferring your products to a bottle which involves inspecting the material, and then conveyors feed it into the machine which then pours it into the vessels using volumetric technology and nozzles before capping them. Bottle filing varies not only in product type but in the size, shape, and material of the container too. Depending on your operation, filling systems may adopt in-line or rotary methods before transferring the bottles to the next stage of processing.

Bottle filling equipment

Inspection of jars and bottles is an essential part of any reliable bottle filling operation. Beverage bottles need to be inspected for foreign objects, contaminants, or any residual liquid before filling. After filling, the bottles need to be checked again to ensure the desired fill level, no leaks or potential label problems. Bottles generally travel along conveyors that feed them into the system whereby non-contact optical inspection takes place. This process is usually automated and uses technology to scan the bottles for any potential issues. Considerations for selecting bottle inspection equipment include the size, shape, and material of the bottles, production speed, and the relevant inspection parameters. Bottle inspection equipment is widely used in the food industry to ensure compliance with quality control procedures as well verification.

Bottle inspection systems

A bottle sorter automatically sorts empty bottles at high speeds by size, color or shape before filling. A bottle unscrambler receives empty bottles in bulk and positions them on a moving conveyor for further processing. Both pieces of equipment are generally integrated into a complete and automated production line. Considerations for selecting a bottle sorter or unscrambler include the size, shape, and material of the bottles, production speed, and sorting criteria. Bottle sorters and unscramblers are used in the food industry for packaging fruit juices, oils, and other liquid products; in the pharmaceutical industry, they are used for the filling of vials, ampoules, and bottles.

Bottle sorters and unscramblers

When looking for capping equipment, it is crucial to know first which type of capper your product requires. Do you want screw caps, twist-off caps, hand pumps, or push-pull caps on your bottle or container? If you require different cap types for format changeover times can be time-consuming. The bottle cap seals the top opening of a bottle to guard the product against leakage and spoilage and sterility and filling requirements depend on the nature of your product.

Capping

Filling lines are used extensively in all industries, such as food, pharmaceutical, chemical, and cosmetics, to accurately package different products into a container suitable for that product. Although the filling process is at the very end of the production line, it is no less important than the earlier steps. Last but not least, the idiom that dates back to 1382 when John Wyclif wrote the firste the laste, and the laste the firste, indicates just that the last things on a list are just as valuable as the previous ones. In this case, this idiom fits perfectly.

Filling

Industrial washing systems are used to clean and disinfect a variety of items in research and manufacturing facilities. Industrial washers use solvents and cleaning agents with mechanical action to remove deposits and residues from stainless steel machinery components, empty containers, and other soiled surfaces. The selection of an industrial or commercial washer depends on the type of items and surfaces to be cleaned, the type of deposits/residue that is typically present, whether drying is required after rinsing and the level of sterilization necessary. Manufacturers will have cleaning specifications and as a result, require washers to be engineered to meet these specs.

Washing

Bottling equipment draws a measured quantity of your drink, food, or formulation from a holding tank and fills it into bottles. These bottles usually need to be checked, capped, labeled, and sealed for distribution. Bottling solutions differ in product metering system, sterilization level, and bottle type and sealing system depending on your production scale and product format and regulations. Bottling systems are utilized in a variety of industries. For example, in the food and beverage industry as well as in cosmetics and pharma.

Homogenization is the process of reducing particle size in mixtures to improve the consistency, uniformity, and stability of the product. The choice of a homogenizer depends on the nature of the product, desired particle size, the physical state of the ingredients, and pressure requirements during the process. Homogenization is widely used in the biotech industry for cell lysis and in the pharmaceutical industry for the emulsification of creams and ointments; it also finds applications in the cosmetics and food industries for improving the consistency and uniformity of various products.

A sealed can of beer is the ultimate satisfaction for a craft brewer. But what’s better than a can of beer? A full case ready for the retail shelf. It marks the beginning of a brewing success story, and when cartoning reaches 40 cans per minute, you know you’ve reached your tipping point.

However, as beer packs increase, so do the cartoning challenges. Growing capacity means bringing more hands on deck or investing in an automated system.

Manual operation may have a lower initial cost, but labor costs quickly add up. Moreover, while direct human control allows closer monitoring, automatic cartoners ensure higher consistency. On the whole, machines bring a steady hand.

But automation has a cost too. Mechanical processes open the door to operational and maintenance issues that put the viability of 40 cpm threshold into question.


<h3>Growing by keeping it small</h3>
Small brewers would cheer for a system that combines the simplicity of manual operation with the accuracy of automated systems.

“This need is peculiar to craft brewers,” says Dave Shepherd, president of Mpac Switchback. “Like all businesses, breweries want to expand, but production typically remains around 3,000 barrels a year.”

Backed by decades of experience in beer can cartoning, Dave’s team went on to innovate a solution that achieves both. The Mpac system provides the precision of a machine but without its mechanical complexities.
<h3>A robotic arm lends a hand</h3>
Conventional technology designed for higher speeds involves separate units for erecting, filling, and closing boxes, apart from the intricate tracks connecting them. The Mpac engineers went back to the drawing board and rebuilt a system around a robotic arm that guides the carton every step of the way.

The platform simplifies the cartoning process while perfectly matching the volume requirements of small breweries. Dave explains how the robotic arm eliminates a layer of complexity: “We managed to replace a whole series of electromechanical tools with a single, low-maintenance device.”

40 cpm is a significant breakthrough, but brewers do not need to complicate their line just to keep up with the cartoning demands. The helpful robotic arm takes your production from tipping point to sipping point without mechanical hangovers.

Advantage craft breweries: robots take the frothiness out of cartoning

Find processing technology for making energy drinks and connect with a global network of leading equipment suppliers.

Find production technology for making Energy drinks, and connect directly with leading machine manufacturers worldwide

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Horizontal Beverage Can Cartoner

Tunnel pasteurizer for beverages

Heating and cooling tunnel for beverages

High-capacity carbonated drink filling system

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