1. Solution Overview

This custom automatic line is designed for high-viscosity products like shampoo, conditioner and body wash, adapting to three popular South American round bottle sizes: 355ml, 600ml and 1000ml.

The full-line configuration includes an automatic bottle unscrambler, viscous filling machine, sleeve labeling machine and adhesive labeling machine, realizing one-stop automated production from bottle feeding and filling to dual labeling.

Developed from a real Brazil local factory project, the solution adapts to frequent size switching and mixed small-batch production. All performance data is on-site verified, suitable for B2B promotion and Google display, solving common problems of poor multi-size compatibility, disjointed processes, unstable labeling and heavy labor reliance.

2. Bottle Specification Parameters

All bottles are standard PET/HDPE specifications for South American daily chemical industry. All data is practically measured for equipment debugging and mass production.

3. Production Pain Points

The client is a medium-sized daily chemical manufacturer in São Paulo, Brazil, supplying shampoo and body care products to local supermarkets and wholesalers. Frequent mixed production of three bottle sizes brought obvious limitations from old separate equipment.

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Low changeover efficiency: Manual parameter adjustment for size switching caused long downtime and low order flexibility.

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Viscous material residue: Traditional filling caused wire drawing and bottle mouth residue, requiring manual cleaning and causing inconsistent product appearance.

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Unstable labeling: Big differences between small and large bottles led to label wrinkling, offset and high defective rate during mixed production.

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Disconnected processes: Independent machines required manual semi-product transfer, restricting production efficiency and continuity.

4. Custom Integrated Production Line Solution

We customized a full automatic inline line for high-viscosity care products: Bottle Unscrambler → Viscous Filling Machine → Sleeve Labeling Machine → Adhesive Labeling Machine. Pre-set parameters support one-click switching for 355ml/600ml/1000ml bottles without mechanical modification.

4.1 Automatic Bottle Unscrambler

It automatically sorts, corrects and conveys all three bottle sizes. Pre-stored size data enables fast switching for mixed batches, avoiding jamming and messy feeding. Stable running speed matches the filling host for continuous line feeding.

4.2 Viscous Filling Machine

Preset filling parameters support one-click size change to reduce downtime. Adopting piston filling and reverse suction structure, it effectively eliminates wire drawing and bottle residue without manual wiping. Electric adjustable guide rails adapt to different bottle sizes, ensuring stable filling accuracy and preventing bottle deviation during high-speed operation.

4.3 Automatic Sleeve Labeling Machine

Fast mold switching adapts to 355ml–1000ml bottles with automatic center positioning. Constant-temperature shrinking ensures bubble-free, wrinkle-free and tight label fitting. Synchronized running speed avoids bottle accumulation and fits mass production rhythm.

4.4 Automatic Adhesive Labeling Machine

Installed after sleeve labeling for secondary standard labeling. It automatically adapts to different bottle heights and diameters to correct labeling position, ensuring flat and unified packaging appearance with no stop-line operation.

4.5 Overall Line Advantages

Full stainless steel structure adapts to South American workshop conditions. The simple visual operation system lowers worker training costs. Universal spare parts and low maintenance reduce long-term factory operational expenses.

5. On-site Operation & Improvement Effects

After stable on-site operation, the integrated line completely solved the client’s production bottlenecks, achieving clear improvements in flexibility, quality and cost control:

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One-click size switching eliminates repeated manual debugging, greatly reducing downtime and improving multi-batch order capacity.

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Full automatic bottle feeding cancels manual sorting, saving labor and stabilizing production rhythm.

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Anti-residue filling design improves finished product cleanliness and overall qualification rate.

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Dual labeling process realizes standardized and consistent packaging, meeting high-standard retail requirements.

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Full-line seamless connection removes manual transfer, improving production continuity and stabilizing batch quality.