How to choose a milk bottling line: a practical guide to used, revamped and new equipment

Choosing a milk bottling line is never a simple decision. Budget, volumes, product type, formats, installation times, and compatibility with existing equipment all have a decisive impact on the final outcome.

In this guide, we take a practical look at the three real options available to a dairy or dairy-processing company: purchasing new machines, investing in used equipment, or opting for revamping. With pros and cons, technical examples, and a final checklist to help you make fast, informed decisions.

In this guide, we take a practical look at the three real options available to a dairy or dairy-processing company: purchasing new machines, investing in used equipment, or opting for revamping. With pros and cons, technical examples, and a final checklist to help you make fast, informed decisions.

Milk bottling: a new line, when it is the best solution

Purchasing new machinery remains the most straightforward option when very high performance and state-of-the-art technology are required. It is the right choice if:

• you work with medium-to-high volumes of UHT or ESL milk, where microbiological safety is a top priority
• you are looking for advanced automation, lower consumption, and reduced operating costs
• you want a system designed specifically for the layout, routes, and flows of your plant

Pros – new milk bottling plant

• High performance and reliability
• Easy integration with traceability solutions, quality controls, and CIP/SIP
• Customizable configuration when starting from scratch
• Fully documented system from the manufacturer (useful for teams with limited experience)
• Latest-generation software (often oversized compared to actual needs)

Cons – new milk bottling plant

• Very long delivery times (6–12 months)
• Very high initial investment
• Spare parts availability less immediate
• Greater electronic complexity, requiring more highly trained personnel
• Slower ROI, especially in dairies with medium volumes
• Difficulty integrating into existing layouts

When it makes sense: new high-productivity lines, UHT production, complex layouts requiring dedicated design.

In short: new equipment makes sense only when designing a completely new plant with very high volumes. In all other cases, it often represents an unnecessary luxury.

Used line: a concrete alternative to reduce costs

Used milk bottling lines offer a concrete alternative for those who want to reduce costs without sacrificing quality. The used equipment market in the dairy sector is mature and allows sourcing PET blow molders, fillers, labelers, packers, cartoners, and conveyors that are already proven.

Pros – used milk bottling line

• Investment reduced by 40–60% compared to new, with a much faster ROI
• Performance comparable to new equipment with proper mechanical and electronic revamping
• Lower consumption even on used machines, thanks to upgrades to motors, inverters, and control systems
• Easier spare parts availability, as machines belong to widely used platforms
• Greater flexibility in case of expansions, new formats, or product changes
• Lower software complexity and simpler maintenance

Cons – used milk bottling line

• Requires professional refurbishment (not “as-is” used)
• Need to verify format compatibility, electrical systems, and layout
• The exact desired model is not always available

When it makes sense: rapid expansions, replacement of a faulty machine, new lines with a limited budget.

Revamping: when refurbishing an existing in-plant machine is better than buying new

Revamping is the optimal choice when the goal is to achieve “almost new” machine performance at significantly lower costs.

It is a deep technical intervention that includes:

• replacement of critical components (bearings, conveyors, electronics)
• complete mechanical overhaul
• PLC and electrical panel upgrades
• adaptation to newly required formats
• testing, commissioning, and certifications

When does revamping really pay off?

There are three situations where revamping is the smartest choice:

1. When you need to increase performance without replacing the entire plant
2. When you need to adapt the line to a new format. PET milk, HDPE, multipack clusters, or volume changes: often upgrading is more convenient than buying new.
3. When operating margins do not justify a new line. Medium-sized dairies, fresh milk producers, seasonal volumes, or backup lines.

Real-world examples that show what works

1. Adding new cluster formats – NÖM, Austria

Problem: NÖM needed to introduce two new cluster formats (1×3 and 2×2) while maintaining 12,000 bph in a very limited space. BBM solution: installation of a used and overhauled cluster packer, integrated with a custom divider, enabling fast format changeovers without replacing screws, with intuitive adjustments via color-coded knobs. Installation and commissioning were completed in just a few weeks, with the addition of a marking system requested by the customer.

2. New UHT milk line integrated with used machines – Latteria Soresina, Peschiera Borromeo

Problem: build a new UHT line that could be integrated with the existing one and used as a backup for fresh milk production, ensuring production continuity. BBM solution: layout design and supply of refurbished and guaranteed used machines, including a blow molder adapted to a 38 mm neck finish with dedicated molds, a refurbished shrink wrapper, a labeler, and connecting conveyors. The blow molder was upgraded to process lightweight bottles, reducing plastic usage. Result: capacity of 12,000 bottles/hour in 3×2 and 4×2 formats, a fast and efficient intervention, perfectly integrated without disrupting the existing plant.

3. Fast PET conveyor upgrade and layout optimization – Latteria Valtellina

Problem: optimize an existing PET line and implement a second bottling line connected to the same palletizing system, while meeting very tight production deadlines. BBM solution: design, prototyping, and installation—in just one month—of automatic “cut-and-splice” conveyors, efficiently integrating new and used components, equipped with active transfer plates to ensure smooth and controlled bottle flow. The intervention included independent automation panels, touchscreen PLCs, and targeted machine relocation, optimizing the existing layout and allowing the new line to be added without interrupting production.

These cases show that often the most efficient solution is not “new versus used,” but a well-considered combination of both options.

Explore more success stories in used milk bottling line

Choosing the most suitable solution for milk bottling depends on a balance between performance, investment, and production flexibility.

Decision checklist for milk bottling plant managers

Use it to quickly decide which path to take:

What production volume is required?

• High → New
• Medium → Used / Revamping
• Variable or seasonal → Used

How much time do I have for installation?

• < 2 months → Used (or revamping, only with a fast and flexible partner)
• 3–12 months → Used or revamping
• > 12 months → Used, revamping, or new

My main goal is…

• Reduce costs → Used or revamping
• Increase speed → Revamping or new
• Have a stable and reliable line → Refurbished used or new

Do I have a partner who can handle integration, installation, and commissioning?

• Yes → All options are valid
• No → It is advisable to rely on a partner capable of managing the entire process, from integration to commissioning

Conclusion

There is no one-size-fits-all solution. The best decision comes from a balanced evaluation of investment, timing, production goals, and the flexibility required by the line.

There is no single solution for milk bottling.
The best decision comes from a balanced evaluation of investment, timing, production goals, and the flexibility required by the line.