A leading beverage producer sought a solution capable of handling UHT tea, syrups, juices, and smoothies while meeting strict aseptic standards. The system needed to adapt to various formats (250 ml to 1.5 L), ensure precise dosing, simplify recipe and format changes, and maintain fully traceable production.
Weightpack delivered a fully integrated aseptic solution. At its core is a CombiBlock system that combines blowing, sterilization, net-weight filling, and electronic capping into a single continuous process operating in a controlled ISO 5-classified environment. Additional modules provide automatic sanitization, recipe management, and digital traceability.
The challenge
Processing sensitive beverages demands extreme hygiene, precision, and flexibility. Bottles and caps vary in size and type, fill volumes must be exact, and production must remain sterile. Any deviation could compromise safety, quality, or compliance.
The solution
The integrated aseptic system ensures high-speed, precise, and safe beverage packaging. Key features include:
- Guaranteed total hygiene – advanced cleaning and controlled environments ensure maximum product safety
- Millimetric precision – each bottle receives the exact dose with continuous monitoring to reduce waste
- Zero-hassle cleaning – fully automatic cleaning inside and out, no manual intervention needed
- Format flexibility – fast and easy changeovers with stored digital parameters
- Data always under control – production data, traceability, and reports easily accessible via network or USB
- User-friendly operation – intuitive interface enables smooth supervision
- Safe and sterile environment – aseptic processing with filtered air and integrated sanitization
The Weightpack system handles up to 8,800 bottles/hour (1 L format), PET bottles from 250 ml to 1.5 L, and both screw and snap-on caps. Individual IP69K load cells monitor tare, dosing, and final weight at 1,000 readings per second. Rejects are automatically removed, and statistical reports are generated in real time.
Electronic capping adjusts torque from 0.5 to 5 Nm depending on cap type, suitable even for delicate closures. Sterility is maintained via remote HEPA filters, overpressure, continuous air recirculation, and automatic ozone sterilization.
Thanks to this solution, the producer now operates a highly precise, traceable, and flexible aseptic process for UHT tea, juices, and smoothies. The modular design allows easy expansion and customization while complying with international hygiene standards.
