AH 8000 LPH ISI PACKAGED DRINKING WATER PLANT UNIT FULL SETUP

An 8,000 Liters Per Hour (LPH) ISI-certified packaged drinking water plant is a heavy-duty, high-capacity commercial setup. It generally supports a rinsing, filling, and capping output of around 120 bottles per minute (BPM) or roughly 6,000 to 7,200 bottles per hour for 1-liter bottles.
Estimated equipment and machinery costs for a fully automatic setup typically range from ₹50 Lakhs to ₹1.5 Crores+, depending on the level of automation, specific brand components, and auxiliary packaging gear
1. Raw Water & Pre-Treatment Specifications
• Raw Water Pump: High-capacity stainless steel centrifugal pump (SS 304/316) for feeding raw water from a borewell or municipal source.
• Multi-Grade Filter (MGF): Quartz sand and pebble media to remove suspended solids, turbidity, and physical impurities.
• Activated Carbon Filter (ACF): Granular Activated Carbon (GAC) to absorb chlorine, organic compounds, bad odors, and color.
• Iron Removal Filter (If required): Specialized media if raw water has high ferrous iron content.
• Dosing Systems: Antiscalant dosing system to prevent RO membrane scaling, and raw water chlorination/dechlorination setup.
2. Purification & RO System Specifications
• Reverse Osmosis (RO) Plant: Dual-pass or high-recovery RO system rated for 8,000+ LPH capacity to account for reject water (recovery typically 50–60%).
• Membranes & Housings: High-rejection composite polyamide membranes (e.g., Hydranautics or Dow/Filmtec) with SS pressure tubes.
• High-Pressure Pumps: Multi-stage vertical centrifugal pumps (e.g., Grundfos or equivalent) for RO feed.
• UV Sterilization System: Ultraviolet disinfection chambers post-RO to neutralize residual bacteria.
• Ozonation System: Ozone generator with mixing pump and contact tank to infuse ozone into treated water, ensuring shelf-life sterility required by BIS/ISI standards.
• Remineralization System: Automatic mineral dosing/adjustment system to re-add precise quantities of essential minerals (magnesium, calcium) to meet BIS drinking water norms (IS 14543).
3. Filling & Packaging Line Specifications
• Automatic Rinsing-Filling-Capping Machine (Monoblock): Rotary or linear automatic rinsing, gravity/pressure filling, and screw capping machine (Speed: ~120 BPM for 500ml/1000ml PET bottles).
• Material of Construction (MOC): Food-grade Stainless Steel (SS 304 for body frames and contact parts; SS 316 for critical liquid paths).
• PET Bottle Blowing Machine: Semi-automatic or fully automatic stretch blow molding machine with air compressor and high-pressure boosters (to manufacture bottles on-site).
• Conveyor Systems: Air conveyors for empty bottles and flat-chain stainless steel/PVC conveyors for filled bottles.
• Batch Coding / Printing: Inkjet or laser coding machine for manufacturing date, MRP, and batch numbers.
• Labelaling & Packaging: Automatic sleeve/sticker labeling machine and shrink-wrapping machine for bundle packaging. [1, 2]
4. Utility & Quality Control Lab (Mandatory for ISI/BIS Certification)
• Power Requirement: Approximately 90 kW to 150 kW (3-phase, 415V electrical supply) depending on whether an in-house PET blow molding machine is included.
• In-House Quality Laboratory: Mandatory testing instruments for BIS compliance, including pH meter, TDS meter, incubator for microbiological testing, turbidity meter, colony counter, and chemical titration kits.
• Space Requirement: Minimum 4,000 to 6,000 sq. ft. covered industrial shed separated into raw water area, processing/filling clean room, microbiological lab, and storage zone.