Dust-free feeding · Integrated crushing & mixing · 1 ton per batch

1. Project Background

In Nepal, the market for instant fruit drink powders, energy drinks and carbonated beverages has been growing rapidly. Young consumers are driving demand for convenient, flavorful drink options that can be sold through supermarkets, convenience stores and small shops across the country.

Our customer for this project is one of the top three beverage companies in Nepal, operating multiple well-known local brands, including:

• A “Nepal-style Red Bull” energy drink;

• A local “Coca-Cola type” carbonated soft drink brand;

• Several juice and fruit-flavored beverage products widely distributed nationwide.

To expand their portfolio of solid instant drink products, the customer decided to build a dedicated fruit drink (“fruit granules / fruit instant”) powder line, turning fruit powder and sugar into a uniform, ready-to-pack flavored powder base for their branded products.

2. Customer Profile & Application

Customer type:
A leading Nepali beverage group (top 3 in the country), with multiple production lines for energy drinks, CSDs (carbonated soft drinks), bottled water and juice beverages, and strong national distribution channels.

Production line application:

• Processing various fruit powders (lemon, orange, mango, etc.) together with refined sugar and other minor ingredients;

• Completing the full process on one line: dust-free feeding → sugar crushing → recipe mixing, to obtain a homogeneous fruit drink powder;

• Supplying this fruit drink base powder to their own sachet and canned instant beverage packaging lines.

Key pain points and requirements:

1. Large batch capacity with stable output – target 1 ton per batch to handle peak season demand;

2. High mixing uniformity for fruit powder + sugar, so the final drink is neither “too sweet” nor “too weak” batch to batch;

3. Dust control during feeding and crushing to improve workshop environment and support brand and audit requirements;

4. Food-grade construction with easy cleaning and fast flavor changeover (lemon, orange, mixed fruit, etc.).

3. Our Solution (Process & Line Configuration)

After analyzing the customer’s product portfolio, formulation characteristics and plant layout, we supplied a complete:

Fruit Drink Powder Crushing & Mixing Line
(Dust-free feeding + sugar crushing + high-efficiency mixing, 1 ton per batch)

(1) Dust-free Feeding System

• Equipped with a dust-free feeding station, where operators place and open bags of sugar and other powder ingredients inside an enclosed chamber;

• An integrated dust collection system captures airborne sugar dust and lightweight powders during dumping and returns them to the product stream;

• This significantly reduces dust escape in the production area, improving working conditions and helping the plant present better hygiene during audits and customer visits.

(2) Sugar Crushing & Pre-treatment

• Coarse sugar is conveyed (by screw or vacuum conveying) from the feeding station to the crushing mill;

• Crushing fineness is set according to the formulation requirements, aiming to match the sugar particle size to the fruit powder as closely as possible, reducing segregation and layering;

• The crushed sugar is transferred to the mixing section through closed piping, avoiding secondary dust and manual handling.

(3) High-Efficiency Mixing System

• Crushed sugar, fruit powders, acids, vitamins and other minor ingredients are dosed according to the recipe and fed into the mixer;

• A high-efficiency mixer (horizontal or vertical, optimized for the customer’s layout) combines tumbling and gentle shear to achieve high uniformity for 1-ton batches within a reasonable mixing time;

• The internal surfaces of the mixing chamber are rounded and polished to reduce sticking and powder build-up, and to simplify cleaning between flavors.

(4) Food-Grade & Easy-Clean Design

• All product-contact parts are made from 304 stainless steel, meeting food and beverage standards;

• Key sections are fitted with inspection doors and quick-release structures, allowing fast access for cleaning and visual checks;

• The control system is designed with recipe management in mind, so different fruit flavors can be associated with specific process parameters and easily recalled.

4. Key Technical Data (Excerpt)

5. Initial Customer Feedback

After installation, commissioning and several rounds of trial production, the Nepali customer provided very positive feedback:

1. More stable taste and quality

   • Fruit drink powder produced on the new line shows much better consistency in sweetness, acidity and fruit flavor compared with earlier small-scale production;

   • The reconstituted drinks now exhibit more uniform color and taste, reducing the risk of complaints like “this batch is too light” or “that batch is too sweet.”

2. 1-ton batch capacity eases peak-season pressure

   • With 1 ton per batch and multi-shift operation, the line can keep up with high-season orders much better than multiple small mixers;

   • Centralized production makes planning and inventory control easier than managing many small, separate batches.

3. Dust-free operation supports brand and audit image

   • The dust-free feeding station and closed transfer significantly cut visible dust in the workshop, improving the working environment;

   • When hosting brand partners or auditors, the customer can confidently showcase the fruit drink powder line as a benchmark for hygiene and process control.

4. Fast flavor changeover enables flexible product development

   • The all-stainless, easy-clean design allows quick switching between flavors (lemon, orange, mixed fruit, etc.);

   • This supports small trial runs for new flavors, then fast scale-up once the market response is confirmed.

6. Conclusion

This fruit drink powder crushing & mixing line for Nepal was engineered around four core requirements:

High batch capacity, excellent mixing uniformity, dust-free production, and easy cleaning/changeover.

By integrating dust-free feeding, sugar crushing and high-efficiency mixing into a single line, it helps the customer to:

• Improve flavor and quality consistency for their fruit instant drink products;

• Increase effective capacity during peak demand periods with 1-ton batches;

• Enhance workshop hygiene and audit performance, in line with their top-tier brand positioning;

• Support rapid flavor development and portfolio expansion through fast cleaning and changeover.

For other beverage manufacturers planning or upgrading instant drink powder (fruit drink, vitamin drink, energy drink powder, etc.) lines, this kind of “dust-free feeding + crushing + mixing integrated” solution is a practical path from traditional small-scale processing to large-scale, standardized production.