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The Proposed Solution: Balanced Automation
One-Stop Service: From Equipment to Consumables
Why Choose PestoPack for Water Filling Projects
More About Our Water Filling Machines
Syria Project Highlights at a Glance
In May 2025, after a detailed factory inspection and technical discussions, a new partnership began between PestoPack Machinery and a water-bottling investor in Deir Ezzor, Syria.
The client had a clear goal — to build a cost-effective water bottling plant capable of producing 2000 bottles per hour (BPH) for three bottle sizes – 330 ml, 600 ml, and 1500 ml (3025 neck).
Rather than pursuing a high-investment automatic line, the customer focused on maximizing return on investment and maintaining flexibility for future expansion.
PestoPack provided the perfect answer: a semi-automatic + automatic hybrid water filling line, integrating essential automation where it adds value most – the 3-in-1 water filling machine – while keeping auxiliary systems semi-automatic to reduce costs.
Country: Syria
City: Deir Ezzor
Project Capacity: 2000 BPH
Bottle Sizes: 330 ml / 600 ml / 1500 ml (3025 neck)
Line Configuration: Semi-automatic + Automatic
Commissioning Date: May 2025
This water line demonstrates how a balanced solution can achieve professional results even with limited capital — a model suitable for small and medium-scale water producers across the Middle East, Africa, and Central Asia.
Before the project began, the Syrian customer emphasized several key expectations:
High cost-performance ratio – equipment needed to be reliable, durable, yet affordable.
Flexible production – handle multiple bottle sizes easily with simple changeovers.
Compact footprint – suitable for a modest workshop with limited utilities.
Ease of operation – operators with basic technical training should manage daily tasks.
Availability of consumables – preferably a one-stop supplier for preforms, labels, and PE film.
With regional logistics constraints and high import duties, it was crucial to deliver a turnkey yet economical water bottling line that met these expectations.
After evaluating several configurations, PestoPack designed a custom 2000 BPH semi-automatic water filling line that combines efficiency with affordability.
The final scope of supply included the following key components:
Every pure-water production starts here.
The supplied 2-ton-per-hour water treatment system guarantees clean, safe drinking water suitable for bottling.
Main Features:
Entire filtration tanks, pipelines, and fittings constructed from stainless steel 304, ensuring long-term corrosion resistance.
Multi-stage filtration – quartz sand filter, activated carbon filter, precision filter, and reverse osmosis membranes for high-quality purification.
Automatic backwash and rinse functions to minimize maintenance.
Compact skid design for quick installation and easy cleaning.
This system delivers stable, hygienic water quality for all three bottle sizes and meets Syrian standards for bottled drinking water.
The customer opted for a semi-automatic 4-cavity blow molding machine to produce PET bottles in-house.
Advantages:
Suitable for 330 ml, 600 ml, and 1500 ml bottles by simply changing molds.
Requires only two operators – one for preform loading and one for bottle removal.
Heating system uses infrared lamps with energy-saving controls.
Stainless-steel blow unit ensures clean bottle formation without contamination.
This configuration provides production flexibility and helps the client avoid dependence on external bottle suppliers.
The heart of the line is the fully automatic 3-in-1 rinsing-filling-capping machine.
It performs bottle washing, filling, and capping within one compact frame.
Technical Highlights:
Gravity filling technology – simple, reliable, and ideal for water.
Food-grade 304 stainless-steel contact parts.
High-precision rotary filling valves ensure consistent volume accuracy.
Bottle neck clamping design avoids bottle deformation.
Adjustable star wheels accommodate different bottle heights.
Siemens PLC control with automatic start-stop, fault alarm, and easy touchscreen operation.
By automating this stage, the line ensures high hygiene standards and stable output at 2000 BPH, while upstream and downstream operations remain semi-automatic for cost efficiency.
Labeling is one of the most visible aspects of bottled-water branding.
The client required a simple yet professional shrink labeling system.
PestoPack supplied a semi-automatic sleeve labeler with steam shrink tunnel and steam generator.
Features:
Manual label feeding – ideal for small production scales.
Heat-shrink tunnel uses steam for uniform shrinkage and glossy finish.
Suitable for PVC, PETG, or OPS shrink sleeves.
Easy adjustment for various bottle diameters.
Energy-efficient stainless-steel structure.
This system gives bottles a professional retail appearance without the cost of a fully automatic labeler.
Instead of traditional inkjet systems, PestoPack recommended a laser coder for marking production date and batch code.
Why Laser Coding Is Better:
No consumables – no ink, solvents, or filters to replace.
Maintenance-free – no nozzle clogging or print-head replacement.
High-speed, permanent marking resistant to water and abrasion.
Simple digital control interface for setting date/time formats.
This not only reduces long-term costs but also simplifies operation — a perfect match for semi-automatic production.
The final packaging stage uses a semi-automatic PE film shrink wrapper, where operators manually group bottles before automatic sealing and shrinking.
System Highlights:
Suitable for 3×2 or 4×3 bottle packs.
Uses PE film supplied by PestoPack as part of the one-stop solution.
Equipped with high-efficiency heating tunnel for clear and tight shrink effect.
Compact design with easy maintenance and stable temperature control.
This packaging stage completes the line, allowing finished packs to be palletized for distribution.
Beyond machinery supply, PestoPack provided complete project support to ensure the Syrian customer could start production smoothly.
Our engineering team created a factory layout tailored to the client’s available workshop space, optimizing equipment flow, utilities, and operator convenience.
We also designed custom bottle shapes balancing aesthetics, mold cost, and stability on conveyors.
To make the startup process seamless, we delivered supporting consumables, including:
Bottle preforms
Shrink labels
PE shrink film
This minimized the client’s sourcing burden and guaranteed perfect material compatibility with the machines.
The result is a stable and efficient 2000 BPH water bottling line now operating in Deir Ezzor.
The client reports consistent output and simple operation even with limited local resources.
By combining semi-automatic and automatic elements, the project achieved over 30 % cost savings compared with a fully automatic line, while maintaining reliable performance.
The customer appreciated PestoPack’s transparent communication, precise engineering, and comprehensive support —from layout planning to spare parts and consumables.
Aspect | Benefit |
Investment Efficiency | Lower initial cost while maintaining essential automation |
Operational Simplicity | Fewer operators, user-friendly controls |
Product Quality | Consistent filling accuracy and professional packaging |
Energy Efficiency | Optimized heating and air-consumption systems |
Expandability | Can later upgrade to full automation without equipment replacement |
This modular design allows small producers to start small, grow big, scaling step-by-step as their market expands.
PestoPack Machinery is a leading manufacturer of liquid filling, bottling, and packaging solutions, serving global customers across the water, beverage, oil, and chemical industries.
Our Advantages:
Factory-direct pricing — no middlemen, maximum value.
Over 20 years of experience in complete production lines.
ISO 9001 and CE certified manufacturing.
Projects in 30 + countries — from Africa to Europe to Asia.
One-stop service — equipment + layout + raw materials + training.
Whether you’re an established brand or a startup investor, we provide tailor-made water filling lines that fit your production goals and local market needs.
If you are exploring similar capacities or higher throughput, PestoPack offers multiple configurations:
Water Filling Machines – From 1000 BPH to 36000 BPH, including 3-in-1 rinse-fill-cap systems for PET and glass bottles.
Water Bottling Lines – Complete turnkey lines covering treatment, blowing, filling, labeling, coding, and packaging.
Each line can be customized according to bottle volume, cap type, label material (OPP, shrink sleeve, or adhesive sticker), and final packaging (film wrap or carton).
Factory Inspection: Completed in May 2025
Location: Deir Ezzor, Syria
Capacity: 2000 BPH
Bottle Sizes: 330 ml / 600 ml / 1500 ml (3025)
Core Machine: Automatic 3-in-1 Water Filler
Supporting Machines: 2 T/h RO System, 4-cavity blow molder, semi-auto sleeve labeler, laser coder, semi-auto PE wrapper
Materials Provided: Preforms, labels, PE film
Service Scope: Design + Supply + Layout + Consumables
Objective: High cost-performance, easy operation, compact footprint
This project serves as an inspiring model for entrepreneurs in developing regions seeking to enter the bottled-water market without massive investment.
“PestoPack provided exactly what we needed — a professional solution at a reasonable price.
The equipment runs smoothly, the bottles look great, and their team supported us every step of the way.”
— Syrian Client, Deir Ezzor Water Plant (2025)
The 2000 BPH Water Filling Line in Syria is more than a single project — it represents a scalable and smart investment model for growing water brands in developing markets.
By combining essential automation with manual flexibility, PestoPack helps investors reduce startup costs while maintaining professional quality and market-ready packaging.
If you are planning to establish your own bottled water production line, PestoPack Machinery can design a customized solution that meets your capacity, budget, and local conditions.
Contact Us Today to receive your factory layout plan and bottle design proposal for your upcoming project.
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