Client Overview
TropiFresh Beverages is a well-known local juice manufacturer based in Jakarta, Indonesia, focusing on 100% natural tropical fruit juice products including mango, pineapple and guava. With the rapid growth of Indonesia’s healthy beverage market, the client won long-term supply contracts with multiple national supermarket chains and convenience store channels. However, its original semi-manual production line suffered from low output, high raw material loss and unstable sterilization effect, which became the core bottleneck of business expansion.
Core Challenges
- Low juice yield: The original manual juicing process resulted in over 25% fruit waste, pushing up raw material costs significantly.
- Sterilization instability: Unstable pasteurization effect led to a short shelf life of only 30 days under normal temperature, which could not support long-distance distribution.
- Low automation level: High reliance on manual labor led to unstable product quality and low production efficiency.
Customized Full-Automatic Juice Production Solution
Allylinkmachine designed a complete turnkey juice production line tailored to tropical fruit processing characteristics, covering raw material pretreatment, juicing, filtration, batching, sterilization, filling and CIP cleaning processes.
Table 1: Core Equipment List
表格
| Equipment Name | Specification | Quantity | Core Function |
|---|---|---|---|
| Fruit Bubble Washing Machine | 5T/h | 1 set | Surface cleaning of fresh fruits, removing sediment and pesticide residues |
| Screw Juicer & Crusher Unit | 5T/h | 1 set | Fruit crushing and squeezing, suitable for mango, pineapple and other soft fruits |
| Precision Filtration System | 5T/h | 1 set | Remove pulp residue, obtain clear juice with uniform taste |
| Stainless Steel Batching Tank | 3000L | 3 sets | Juice blending, sugar and additive proportioning |
| Plate Pasteurizer | 5T/h | 1 set | Low-temperature sterilization, retain fruit flavor and extend shelf life |
| 3-in-1 Atmospheric Filling Machine | CGF16-12-6 | 1 set | Integrated bottle rinsing, normal pressure filling and capping for PET bottles |
| Security Filter | 1μm & 0.45μm | 2 sets | Pre-filtration protection for sterilizer and filling nozzles |
| Automatic CIP Cleaning System | CIP-80 | 1 set | In-place cleaning of pipelines and tanks, ensure food safety |
| Shrink Sleeve Labeling Machine | TB-120 | 1 set | Full-body label application and heat shrinking |
Project Investment Breakdown
Table 2: Total Investment Structure
| Item | Amount (USD) | Proportion |
|---|---|---|
| Core production equipment | 338,400 | 80.0% |
| On-site installation & commissioning | 38,000 | 9.0% |
| Process formula & technical training | 26,000 | 6.1% |
| Spare parts & consumables kit | 15,900 | 3.8% |
| International logistics support | 4,700 | 1.1% |
| Total | 423,000 | 100.0% |
Project Outcomes & Operational Performance
The whole project was completed and put into full production within 55 days, with all indicators exceeding the client’s expectations.
Table 3: Performance Data Comparison
| Indicator | Before Upgrade | After Upgrade |
|---|---|---|
| Hourly output (500ml PET) | 1,800 bottles | 8,000 bottles |
| Fruit juice yield | 72% | 84% |
| Product pass rate | 94.2% | 99.1% |
| Normal temperature shelf life | 30 days | 9 months |
| Unit labor cost per 1000 bottles | 12.5 USD | 3.8 USD |
| Daily effective operating hours | 8h | 18h |
| Monthly maximum output | 432,000 bottles | 2,880,000 bottles |
Client Feedback
“Allylinkmachine’s professional juice processing solution has completely solved our production bottleneck. The screw juicer greatly improves the juice yield of tropical fruits, and the pasteurization system perfectly retains the fresh fruit flavor while extending the shelf life. With this production line, we have successfully entered 120+ supermarket outlets across Indonesia, and our sales volume has tripled within half a year.”
