Client Background
HerbalViet is a well-established herbal beverage manufacturer based in Ho Chi Minh City, Vietnam, with over 10 years of experience in producing traditional herbal tea drinks made from honeysuckle, chrysanthemum, monk fruit and other local botanical ingredients. As consumer demand for healthy sugar-free beverages surged, the client secured large-scale supply contracts with 4 national supermarket chains and over 200 convenience stores across southern Vietnam. Its original semi-automatic production line, with an output of only 6,000 bottles per hour, suffered from low extraction efficiency, unstable sterilization and high labor costs, becoming the biggest bottleneck for business growth.
Core Operational Bottlenecks
- Low extraction efficiency: Traditional single-tank extraction resulted in only 65% utilization of active herbal ingredients, pushing up raw material costs and weakening product flavor.
- Unstable product shelf life: Inconsistent sterilization led to a short 6-month shelf life, making long-distance distribution and off-season storage difficult.
- Insufficient capacity & high labor reliance: Manual batching and semi-automatic filling caused frequent quality fluctuations, and output could not keep up with channel order growth.
Full-Automatic Turnkey Solution from Allylinkmachine
Targeting the client’s capacity requirements and herbal tea processing characteristics, Allylinkmachine delivered a complete turnkey production line covering raw material pretreatment, herbal extraction, filtration, batching, sterilization, filling and automatic CIP cleaning. The entire line adopts food-grade stainless steel design, fully complying with Vietnam food safety production standards.
Table 1: Core Production Equipment List
| Equipment Category | Equipment Name | Specification | Quantity |
|---|---|---|---|
| Water Treatment | Single-stage RO Water Purification System | 20T/h | 1 set |
| Extraction System | Multi-stage Countercurrent Herbal Extraction Unit | 10T/h | 1 set |
| Filtration System | Precision Security Filter + Disc Filter | 10T/h | 2 sets |
| Batching System | Stainless Steel Magnetic Stirring Batching Tank | 5000L | 3 sets |
| Sterilization System | UHT Ultra-high Temperature Instant Sterilizer | 10T/h | 1 set |
| Filling System | 3-in-1 Hot Filling Machine (Rinsing-Filling-Capping) | 20000BPH | 1 set |
| Cleaning System | Automatic CIP In-place Cleaning System | CIP-200 | 1 set |
| Post-packaging | Sleeve Labeling Machine + Inkjet Printer + Shrink Wrapper | 20000BPH | 1 set each |
Table 2: Total Investment Breakdown
| Investment Item | Amount (USD) | Share |
|---|---|---|
| Core production line equipment | 526,400 | 80.0% |
| On-site installation, commissioning & pipeline laying | 65,800 | 10.0% |
| Process optimization & operator technical training | 39,500 | 6.0% |
| One-year spare parts & consumables package | 19,700 | 3.0% |
| International logistics & customs clearance support | 6,600 | 1.0% |
| Total Project Investment | 658,000 | 100.0% |
Project Outcomes & Performance
The project was officially put into full production within 70 days, 3 days ahead of the scheduled construction period.
- Capacity leap: 500ml PET bottle output reaches 20,000 bottles per hour, 233% higher than the original production line; daily output exceeds 320,000 bottles under 16-hour operation.
- Process improvement: Multi-stage countercurrent extraction increases the active ingredient extraction rate of herbal raw materials from 65% to 83%, and raw material cost per unit product is reduced by 17%.
- Quality stability: UHT sterilization technology extends the normal-temperature shelf life to 12 months, and the product pass rate is stable at 99.4%.
- Labor optimization: Full-line automation reduces front-line operators by 58%, and unit labor cost drops by 62%.
Client Feedback
“Allylinkmachine’s turnkey solution has completely upgraded our production capacity and product quality. The countercurrent extraction system not only saves a lot of herbal raw materials, but also makes the tea taste richer and more stable. With this production line, we have successfully expanded to northern Vietnam markets and become one of the top three local herbal tea brands.”
