BPF-22H : PuzzleFiller 2+2 | The counter-pressure semi-automatic bottle filler and capper 300-400 bph

The PuzzleFiller 2+2 is a simple compact isobaric bottle filler and capper with capacity of 300-400 bottles per hour. The machine is designed for semi-automatic filling carbonated drinks such as beer, cider, carbonated wine, soft drinks, cola, carbonated mineral water. It is allowed to use the machine for filling other carbonated or non-carbonated low-viscosity beverages and food liquids.

The unit is intended to be connected to a keg or a tank by pipes and connectors included in the delivery set.

The PuzzleFiller 2+2 is designed to filling glass bottles with a diameter from 54 mm till 69 mm and a capping the bottles with standard 26 mm crown cap. In one operation cycle, the machine provides simultaneous filling and sealing of two bottles.

The principle of the filling machine

Depending on the degree of carbonation of the drink, the temperature of the drink and the volume of the bottles, the filling capacity is flexibly adjustable with the programmable beverage doser and can be adjusted during the filling process directly by the operator on the touch LCD panel.

To achieve a maximal possible filling speed the carbonated beverages, the absence of foam and the achieve only little inert gas loss, the principle of filling with “counter pressure” is applied – the isobaric filling.

The device offers a choice of different fill quantities, optionally manually filling other quantities, capacity is about 350-400 bottles of 0.33 liters / hour or 200-300 bottles of 0.50 liters. Bottle closure unt is designed only for standard crown caps with diameter of 26 mm.

Simple bottle move system (Puzzle Bottle Carriages)

The PuzzleFiller combinates the manual and the automatic moving between four positions of two adjustable “Puzzle Bottle Carriages”

Bottle carriage

1. Stops – set the distance from the edge of the work table to the stand
2. Stop adjustment screw – used to center bottles under the filling and capping units
3. Bottle diameter adjustment screw

Six steps of the filling process

1. MM-EB : Manual move of the bottle carriage from the the start position to the filling position (with empty bottles)
2. F : Filling station (Automatic counter-pressure filling the empty bottles)
3. AM1 : Automatic move of the bottle carriage from the filling unit to the capping unit
4. C : Capping station (Automatic closure the full bottles with crown caps)
5. AM2 : Automatic move of the bottle carriage out from the capping unit (with the full and closed bottles)
6. MM-FB : Manual move of the bottle carriage to the start position (exchange the unloading full bottles for the new empty bottles)

Main parts of the machine

1. cycle start button (left)
2. filling speed control valve
3. filling assembly
4. transparent protective shield
5. filter-regulator
6. compressed air inlet
7. emergency stop button
8. touchscreen
9. quick-adjust buttons for fill volume
10. capping assembly
11. pneumatic pusher
12. movable bottle supports (Puzzle Bottle Carriages)
13. work table
14. work table height locking mechanism
15. work table height adjustment mechanism
16. aluminum frame
17. locking casters

Semi-automatic control system with the touch LCD

The device is manufactured in accordance with CE standards.
The control panel is equipped with the built-in 5-inch LCD screen controlled by a micro processor, which graphically displays the operation, reports any errors, prevents operation without proper conditions, and warns of malfunctions, while offering a variety of manual settings and functions.
It displays the current and total quantity of bottles produced, liters and operating time.

Flexible construction of the machine

The housing is made in combination of aluminum and stainless material. Built-in height adjustable work bench with scale allows you to set height of the filling and capping heads according to different heights of bottles.

The advantages of the PuzzleFiller 2+2

• easy handling
• quick change of filling volume
• fast setting different sizes of bottles sound notifications
• written notification on the color LCD with a graphic display
• de-oxidation the bottles
• easy LCD-guided cleaning
• touch-LCD control panel

Technical parameters :

• Carbonated beverage products : beer, cider, sparkling wine, soft drinks, soda water etc.
• Still beverage products : water, lemonades, cola drinks, fruit drinks etc.
• Maximal output capacity for 0.33 L bottles : approximaly 350-400 bottles per hour
• Maximal output capacity for 0.50 L bottles : approximaly 200-300 bottles per hour
• Pressure air requirement : 6.5 bar / 5-10 liters per minute
• Beverage input : 3/8″ (9.5mm) feed tube (Quick Hose Coupler) | (temperature from 1°C to max 3°C)
• Pressure air input : 5/16″ (6mm) feed tube (Quick Hose Coupler)
• Carbon dioxide input : 3/8″ (9.5mm) feed tube (Quick Hose Coupler)
• Crown caps : Standard 26 mm / Optionaly 29 mm
• Height of the bottles : from 195 mm up to 320 mm
• Diamerer of the bottles : from Ø 54 mm up to Ø 69 mm

Machine dimensions

• Height: 1610 mm
• Depth: 680 mm
• Width: 700 mm

Frequently Asked Questions :

• Is sterile compressed air required? – no
• Is it possible to purchase optional parts for handling 29mm caps? – yes
• Can the machine also be used to fill non-carbonated beverages? – yes
• Is the fill level determined by flow measurement or by the opening time of the filling valve? – flow meters
• Is the machine equipped with safety mechanisms and sensors to prevent operator injury from pneumatically operated components? – yes

The price includes

• 2 pcs of the universal clamping bottle attachments – Ø 54 mm to Ø 69 mm, height of bottles 195 mm-320 mm
• 3 m of the insulated supply pipe 3/8 “with tank connection ½” – inner thread (connection to the source tank or keg is provided by the buyer)
• 3 m of the food 3/8 “feed tube of CO2 gas
• 3 m of the pneumatic tube Ø 6 mm for air supply
• basic set of spare parts-seals, fittings (according to the list)
• samples of cleaners and disinfectants
• air control group with condensate discharge filter and pressure relief valve
• two plastic puzzle-carriages for 2+2 bottles
• automatic feeding the bottles between the filling and closing heads
• manual insertion of crown caps
• operation manual
• CE Declaration of Conformity
• The machine is designed and manufactured according to the requirements : Machinery Directive 2006/42/EC

Commercial conditions

• Delivery period is usualy 10-12 weeks.
• Payment conditions : 50% when it is ordered, 50% before delivery.
• Warranty : 12 months (on-site services are not included)

How the PuzzleFiller 2+2 works  (video) :