Case Studies

Case studies: water, tea & juice
filled with our aseptic filling machines for PET bottles

Since 1994, DNP has applied its proprietary aseptic filling technology to PET bottles, launching Japan’s first hydrogen-peroxide PET sterilization system. We’ve since delivered over 200 systems worldwide—capturing 60 % of the domestic market—and supply a full range of PET preforms. Our complete aseptic lines deliver the most sterile and eco-friendly product quality. Below are three case studies—water, tea and juice—showing our aseptic filling machines for PET bottles in action.

Tea filling machine case study – 36,000 bph PET bottle line at Shizuoka soft-drink plant (Japan)

Mount Fuji overlooks Shizuoka plant using DNP Green Aseptic non-heated water sterilization for tea

A major beverage producer in Shizuoka began commercial tea production in April 2024 using DNP’s Green Aseptic PET-bottle system. Concentrated tea extract is first heat-sterilized in a small UHT sterilizer and then diluted with sterile water produced by non-heat sterilization that combines medium-pressure UV lamps (Atlantium HOD) and 0.1 µm sterilization filters. After aseptic blending, the line fills 500ml bottles at 36,000bph, with the same non-heated sterile water replacing all conventional rinses. Three media-fill runs of over 10,000 bottles each showed zero spoilage, while the process cuts energy use and CO₂ emissions by roughly 80 %, setting a new sustainability benchmark for low-acid beverages.

Juice filling machine case study – 54,000 bph PET bottle line at Asahi Nagoya (Japan)

Mitsuya Cider, Wilkinson Tansan and Calpis Water PET bottles filled on DNP’s aseptic PET bottle line

Asahi Breweries’ Nagoya factory commissioned DNP’s aseptic PET bottle filling system in April 2021 to produce carbonated and non-carbonated beverages for its Mitsuya Cider, Wilkinson and Calpis brands. An energy-saving blow molder and aseptic carbonation filler sterilize bottles with H₂O₂ gas at around 50 °C, while a 30 m³/h UHT sterilizer feeds product to fill 500ml at 54,000 bph (20,000bph for 1.5L); media-fill tests of over 30,000 bottles confirmed sterility with zero spoilage. DNP’s patented CSIP technology runs CIP and SIP simultaneously in under two hours per changeover, and by eliminating the pasteurizer and using normal-pressure PET bottles, the system reduces H₂O₂ usage by approximately 40 %, lowers total cost of ownership and cuts CO₂ emissions.

Water filling machine case study – Nongfu Spring infant water PET line (China)

Nongfu Spring 1-L infant mineral-water PET bottle produced on DNP’s aseptic line

Nongfu Spring, China’s largest packaged-water brand, launched a 1 L natural mineral water for infants in 2015 by installing DNP’s aseptic filling system for PET bottles. The line achieves sterile bottles and caps without any chemicals and cleans the aseptic chamber with sterile water supplied from multiple UHT sterilizers. Sterility was validated on Nongfu’s specially shaped, easy-grip bottle blow-molded by KHS. Running at 54,000bph, the shelf-stable product removes the need for chilled logistics, reducing both TCO and CO₂ while fulfilling the brand’s “natural & healthy” promise.