For over a decade, Metson Machines have been designing, manufacturing, and installing high-quality water bottling plants across India. From small startups to industrial-scale operations, our plants range from 30 BPM to 200 BPM, delivering consistent, hygienic, and safe bottled water. Unlike generic articles, we provide insights only a manufacturer can offer — from the engineering of machines to the multi-stage purification process and the ROI you can realistically expect.
What Makes a 30–200 BPM Water Bottling Plant Different
A 30–200 BPM (bottles per minute) plant is a high-speed, automated system that fills, caps, and labels bottles with minimal human intervention. It ensures uniform quality in every bottle, reduces labor costs and human error, can be scaled easily from small operations to industrial plants, and provides fast ROI due to automation and efficiency.
Our Step-by-Step Manufacturing Process
1. Raw Water Collection and Pre-Treatment
We source water from borewells, municipal supply, and natural springs. Every batch undergoes rigorous testing for pH, TDS, hardness, turbidity, and microbial load before entering the purification line.
2. Multi-Stage Purification: The Heart of Our Expertise
We use a five-stage water purification system refined over a decade. Sand Filtration removes sand, silt, and suspended solids, protecting downstream equipment and ensuring clarity. Activated Carbon Filtration eliminates chlorine, odor, color, and organics, improving taste and protecting RO membranes. Reverse Osmosis (RO) removes dissolved salts, heavy metals, and microscopic impurities, keeping TDS levels safe and consistent. UV Treatment kills bacteria, viruses, and protozoa without chemicals. Ozonation prevents recontamination, sterilizes water, and preserves freshness naturally.
Table: Multi-Stage Purification – What We Do
| Stage | Purpose | Customer Benefit |
|---|---|---|
| Sand Filtration | Remove suspended solids | Clear water, protects RO |
| Activated Carbon Filter | Remove odor, taste, chlorine, organics | Fresh-tasting, chemical-free water |
| Reverse Osmosis (RO) | Remove salts, metals, TDS | Safe, pure water |
| UV Treatment | Kill bacteria and viruses | Microbiologically safe |
| Ozonation | Sterilize and preserve freshness | Long shelf life, no chemical residue |
3. Bottle Manufacturing and Sterilization
We either manufacture PET bottles in-house or source high-quality bottles. Each bottle is washed and UV sterilized to ensure no contamination before filling.
4. High-Speed Automatic Filling and Capping
Our lines are designed to run from 30 to 200 BPM with precise volume control and automatic capping, minimizing human contact and ensuring consistent quality.
5. Labeling, Coding, and Packaging
Every bottle is labeled, batch-coded, and packed in cartons or shrink-wrapped, ensuring traceability, hygiene, and brand visibility.
Plant Capacities and Ideal Use Cases
| BPM | Ideal Scale | Automation Level |
|---|---|---|
| 30 BPM | Small-scale startups | Semi-automatic |
| 60 BPM | Medium-scale operations | Semi/Automatic |
| 100 BPM | Large-scale businesses | Fully automatic |
| 150–200 BPM | Industrial-scale plants | Fully automatic, multi-line |
Investment and Profitability
Cost Estimates (INR)
| BPM | Machinery | Land & Civil | Utilities | Licensing & Lab |
|---|---|---|---|---|
| 30 BPM | ₹15–40 lakh | ₹10–20 lakh | ₹3–6 lakh | ₹2–4 lakh |
| 60 BPM | ₹40–80 lakh | ₹20–50 lakh | ₹6–12 lakh | ₹4–8 lakh |
| 100 BPM | ₹80–1.5 crore | ₹50–1.2 crore | ₹12–25 lakh | ₹8–16 lakh |
| 150–200 BPM | ₹1.5–3.5 crore | ₹1–2.5 crore | ₹25–50 lakh | ₹16–30 lakh |
Monthly Operating Costs
Electricity & Water: ₹40,000 – ₹50 lakh depending on capacity
Labor: ₹60,000 – ₹32 lakh
Packaging: ₹1–48 lakh depending on scale
Logistics: Variable
Revenue Streams
Retail bottles (200 ml – 2 L)
Bulk jars (5 L – 20 L)
Private-label partnerships
Institutional and office supply
ROI: Most plants recover their investment within 2–4 years, depending on capacity and market demand.
Sustainable and Eco-Friendly Practices
We prioritize sustainability. Water Recycling & ZLD Systems reuse treated water for cleaning and utilities with no harmful discharge. Solar-Assisted Operations reduce electricity consumption. Eco-Friendly Packaging uses lightweight PET bottles, and we continually research biodegradable and recyclable options.
Why Choose Us
We have over 10 years of expertise in water bottling plant manufacturing. Our plants from 30–200 BPM are customizable to your production needs. We ensure compliance with ISO, BIS, FSSAI, and industry standards. Our deep expertise in multi-stage purification, automatic filling, and sustainable operations makes us a trusted partner. We also provide strong technical support and installation guidance.
FAQs
Q1. Can small startups use a 30 BPM plant?
Yes, our 30 BPM lines are ideal for startups and small-scale operations.
Q2. How fast can a 200 BPM plant produce?
200 BPM can produce up to 12,000 bottles per hour, suitable for industrial-scale demand.
Q3. How do you ensure water quality?
We use multi-stage purification, daily quality checks, and sterilized bottling lines.
Q4. Can I expand my plant later?
Yes, our modular designs allow upgrading from 30 BPM to higher capacities.
Q5. What licenses are required?
BIS, FSSAI, ISO certifications, and local approvals. We guide you through all requirements.
Contact us for your requirements
For over a decade, we have been delivering world-class 30–200 BPM water bottling plants. Our expertise as manufacturers allows us to combine high-speed automation, multi-stage purification, and sustainable operations into every plant. Choosing us ensures reliability, hygiene, and maximum ROI for your water bottling business.
