3,000 BPH Bottled Water Line Upgrade for FRISAR in Mexico
Grupo Plomares S.A. de C.V., based in Acambay, Mexico, produces FRISAR bottled water in 350 mL, 500 mL, and 1 L PET bottles.
The customer initially contacted BRENU for a labeling machine. After an on-site assessment, we identified broader production bottlenecks and proposed a complete bottled water line upgrade.
Project Overview
FRISAR in Mexico, operated a low-capacity bottled water line with significant manual handling. In 2024, the company found BRENU through Facebook, initially seeking a labeling machine.
After an on-site assessment, BRENU identified broader production bottlenecks and proposed an integrated line targeting 3,000 BPH for smaller bottles and 2,000 BPH for 1 L bottles.
Based on the actual factory conditions, BRENU proposed a complete line upgrade for 350 mL, 500 mL, and 1 L PET bottled water.
Final Line Configuration:
- 16-12-6 3-in-1 Rinsing, Filling and Capping Machine
- Line Length: approx. 16 m
- Operators: 2–3 people
- Capacity: up to 3,000 BPH for smaller bottles; approx. 2,000 BPH for 1 L bottles
- Semi-Automatic Film Wrapping Machine
- Bottle Dryer
- Manual Sleeve Labeling Station
- Heat Shrink Tunnel
- Laser Coding Machine
Project Challenge
The technical requirements of this project were not exceptionally complicated individually. The real challenge was integrating several production stages into a practical line while rebuilding the customer’s confidence after an unsuccessful previous equipment purchase.
Challenge 1: Low Automation and Too Much Manual Product Handling
The customer’s original line relied on low-capacity filling, semi-automatic capping, and manual labeling, with products manually transferred between each stage.
As production increased, these disconnected processes limited overall efficiency. Adding a faster labeling machine alone would only shift the bottleneck rather than solve it.
Our Solution: Redesign the Complete Production Flow
After evaluating the factory, BRENU reorganized the production process around a 16-12-6 3-in-1 rinsing, filling and capping machine. The complete line included:
- 16-12-6 3-in-1 rinsing, filling and capping machine
- Bottle dryer
- Manual sleeve labeling station
- Heat shrink tunnel
- Laser coding machine
- Semi-automatic film wrapping machine
We optimized equipment connections and conveyors to create a continuous production flow. The 16-meter line was designed around the available factory space, reducing manual handling and requiring only 2–3 operators.
Challenge 2: Rebuilding Trust After a Failed Equipment Purchase
Before BRENU, the customer purchased a low-cost 3-in-1 filling machine from another Chinese supplier. After a six-month delivery, the machine frequently failed.
The supplier proved to be a trading intermediary with limited technical support. The unusable equipment caused financial losses and damaged the customer’s trust.
Our Solution: Factory Capability + Local Mexican Support
Unlike a typical remote sale, BRENU’s CEO and Mexico team visited the customer’s factory before finalizing the line, ensuring the solution was based on actual production conditions.
For the customer’s three main PET bottle sizes, the equipment and line configuration were adapted through:
- Conveyor adjustments for different bottle formats
- Filling valve configuration optimization
- Bottle-neck handling adjustments
- Easier changeover between bottle sizes
- Production line layout planning according to available factory space
BRENU combines its China-based manufacturing capabilities with a local Mexican branch and engineering team, providing faster communication and technical support while reducing reliance on long-distance assistance.
The Result: From Disconnected Machines to a More Continuous Production Line
The upgraded line transformed FRISAR’s disconnected production stages into a more continuous process, reducing manual handling and improving overall production stability and efficiency.
Key improvements include:
- Production efficiency: increased by approx. 80%–120%
- Labor requirement: reduced by approx. 30%–50%
- Small bottle capacity: up to 3,000 BPH
- 1 L bottle capacity: approx. 2,000 BPH
- Production flow: more stable with less manual transfer
- Expansion: greater flexibility for future bottle sizes and capacity
Beyond improving production, the project rebuilt the customer’s confidence through BRENU’s manufacturing capability, customized engineering, on-site assessment, and local technical support in Mexico.
