A global tequila producer aimed to fully automate the bottling and packaging of tequila in glass and ceramic bottles (200–1,000 ml) at 30 bpm (750 ml), while meeting excise and tamper-evident regulations. The project required managing multiple bottle formats, achieving precise filling, enabling rapid sanitation, and maintaining full traceability.
Weightpack delivered a turnkey, modular line that integrates every stage—despaletization, washing, net-weight filling, capping, shrink sleeve, labeling, and end-of-line—into a seamless system that combines precision, hygiene, and flexibility.
The challenge
Producing tequila across diverse formats demands extreme precision and regulatory compliance. Bottles differ in shape and material, fill volumes must be exact, and sanitation must be fast and thorough. Any downtime, misfill, or hygiene lapse could compromise quality or compliance.
The solution
The modular line ensures consistent performance, hygiene, and control without compromise. Key features include:
- Consistent quality – exact fill volume in every bottle
- Guaranteed hygiene – contact-free operation with integrated CIP cleaning
- Flexible production – rapid, tool-free format changeovers
- Operational efficiency – continuous flow minimizes downtime
- Waste reduction – low rejects and material savings
- Full traceability – real-time monitoring and automated reporting
The system is controlled by an Allen-Bradley CompactLogix PLC, synchronizing all modules for smooth, collision-free operation. Bottles are fed via a bucket-conveyor despaletization system to the WRF 15/12-188 rotary block, where 15 grippers wash with filtered air or hydroalcoholic solution. The net-weight filler employs 12 valves with washable load cells, performing 1,000 readings per second to ensure unmatched accuracy.
A six-head mechanical capper secures bottles with adjustable torque via HMI. All modules meet CE and ATEX standards, and production data can be exported via USB or network through a touchscreen and SQL database.
With this approach, the producer achieved an Industry 4.0-ready line capable of adapting quickly to new formats, maintaining regulatory compliance, reducing waste, and maximizing productivity.
