In modern packaging production, efficiency and flexibility are key to maintaining competitiveness. Many beverage, cosmetic, and pharmaceutical manufacturers rely on automatic bottle filling and capping machines that can handle different bottle types. However, changing from one bottle style to another requires a systematic process to avoid downtime and maintain precision. Understanding how to correctly switch bottle styles on one machine ensures consistent quality, reduced waste, and smooth production continuity.

Understanding the Machine’s Flexibility

Most automatic filling and capping systems are designed with modular components that can accommodate various bottle shapes, diameters, and heights. These include adjustable conveyors, guide rails, changeable star wheels, and interchangeable grippers. When properly configured, the same machine can switch from a short round bottle to a tall rectangular one with minimal manual intervention. Modern machines, such as those produced by BOHANG, feature quick-change mechanisms and intuitive control panels to simplify this transition.

Step 1: Prepare for Changeover

Before initiating a bottle change, the production line must be stopped completely. Operators should remove all remaining bottles from the conveyor and clean the working area to prevent contamination. It is essential to review the production schedule and confirm the specifications of the new bottle, including height, diameter, neck size, and cap type. Having all necessary replacement parts—such as star wheels or infeed screws—ready before the switch minimizes delays.

A well-documented changeover plan helps ensure that every adjustment follows standard procedures.

Step 2: Adjust Mechanical Components

After preparation, operators should adjust the mechanical parts that guide and stabilize the bottles. This includes:

• Conveyor width: The side rails must be moved closer or further apart to fit the new bottle diameter.

• Infeed screw: The spacing between threads must correspond to the new bottle’s height and pitch.

• Star wheel: The pockets should match the shape and neck diameter of the new bottle to ensure precise indexing.

• Capping heads or filling nozzles: Adjust the vertical stroke and alignment to match the new bottle’s height.

On machines equipped with quick-release parts, such as those from BOHANG, these adjustments can often be completed in under 15 minutes, significantly reducing downtime compared to traditional manual setups.

Step 3: Calibrate Sensors and Controls

Every bottle style has different optical and positional characteristics. Therefore, after mechanical adjustments, the sensors and control parameters must be recalibrated. Optical sensors should be repositioned to detect the new bottle’s presence accurately, while photoelectric and proximity sensors must be fine-tuned for height and distance. The control panel settings for filling volume, capping torque, and conveyor speed should also be updated in accordance with the new product requirements.

Many smart machines support recipe-based programming, where each bottle style’s settings are stored and recalled automatically. This feature, commonly available in BOHANG packaging machines, ensures accuracy and consistency across repeated changeovers.

Step 4: Conduct Test Runs and Quality Checks

Before restarting full production, operators should perform several test cycles using sample bottles. These test runs confirm that bottles move smoothly along the conveyor, align correctly under the filling heads, and are sealed tightly without damage or leakage. Visual inspection and weight measurement should be conducted on the first few filled units to verify volume precision and sealing integrity.

A short quality checklist can guide this process:

Once all parameters are within tolerance, the production line can resume normal operation.

Step 5: Record and Optimize Changeover Data

To improve future efficiency, all adjustment data, including rail positions, nozzle heights, and torque settings, should be documented. This information allows operators to repeat successful setups more quickly and helps identify bottlenecks in the changeover process. In factories with multiple product lines, integrating digital monitoring systems can further enhance productivity by tracking each changeover’s time and accuracy.

Regular maintenance and training are also vital. Well-trained technicians can detect subtle misalignments and prevent issues such as cross-threaded caps or bottle jams, which are common during bottle transitions.

Benefits of Using BOHANG Machines for Multi-Bottle Operations

BOHANG offers high-performance filling and capping equipment engineered for fast and precise bottle style switching. Their machines feature tool-free adjustment systems, servo-driven positioning, and memory-based controls. This design reduces changeover time by up to 70% while maintaining filling accuracy within ±0.5%. Whether you operate in the beverage, personal care, or chemical industry, BOHANG’s equipment ensures flexibility without sacrificing efficiency or quality.

Efficient bottle style switching on one machine requires both mechanical precision and digital intelligence. By following a structured process and choosing advanced, modular systems like those from BOHANG, manufacturers can achieve seamless transitions, maintain production quality, and meet the growing demands of diverse product portfolios.