In Ghana, sachet water — locally known as “pure water” — is a daily essential sold on nearly every street corner. For distributors, producing their own sachets rather than reselling is a proven route to higher margins and steady demand.
This case study documents a 2,800 BPH sachet water line that zoolinked mechanical designed and delivered for an established beverage distributor in Kumasi, Ghana who wanted to move upstream into production.
Project Overview
| Item | Detail |
| Location | Kumasi, Ghana |
| Product | 500 ml sealed “pure water” pouches |
| Designed capacity | 2,800 pouches per hour |
| Water source | Municipal supply |
| Plant footprint | Approx. 110 m² |
| Operators required | 2 per shift |
| Scope | Turnkey: design, manufacturing, installation, commissioning, training |
1. Project Background & Client Requirements
The distributor already had strong retail channels but relied on third-party sachet supply with thin margins and inconsistent quality.
By producing in-house, the client aimed to control quality, secure supply and boost margins, while meeting Ghana Standards Authority drinking water requirements.
The client set several clear requirements for the project:
- Reliable output of around 2,800 pouches/hour to feed existing channels
- Consistent seal quality and hygiene to protect the brand
- Water quality meeting Ghana Standards Authority requirements
- A compact line fitting a ~110 m² building
- Simple operation for a small in-house team
2. Raw Water Analysis
Our engineers reviewed the municipal water report. The supply carried chlorine, moderate hardness and seasonal turbidity, shaping the treatment design:
- Chlorine/odor: present → activated carbon filtration
- Turbidity: seasonal → multi-media pre-filtration
- Hardness & TDS: moderate → softening + RO
- Microbial safety: UV + ozone dual disinfection
3. Turnkey Solution & Process Flow
zoolinked mechanical supplied a complete sachet water line. The full process flow is:
- Municipal water tank → feed pump
- Multi-media (sand) filter — removes turbidity
- Activated carbon filter — removes chlorine and odor
- Water softener — protects RO membranes
- 5 µm security filter
- Reverse osmosis (RO) — stable low-TDS purified water
- Purified water storage tank (SUS304)
- UV + ozone disinfection
- Automatic sachet filling & sealing machine — 2,800 pouches/hour
- Date coding → shrink-wrap packing
4. Equipment Configuration
The line was configured for reliable, hygienic production:
| Equipment | Specification / Function |
| Multi-media filter | Removes turbidity & solids |
| Activated carbon filter | Removes chlorine and odor |
| Water softener | Automatic resin softener |
| RO system | 2 m³/h low-TDS output |
| Purified water tank | SUS304 sanitary storage |
| UV + ozone disinfection | Dual sterilization |
| Automatic sachet machine | Form-fill-seal, 2,800 pouches/hour |
| Coding & packing | Date coder + shrink-wrap |
5. Installation & Commissioning
After factory testing, the line was installed in the client’s 110 m² building. Installation and commissioning took about two and a half weeks, including:
- Positioning and connecting the treatment skid and RO
- Setting up the storage tank, UV and ozone
- Installing and calibrating the sachet machine
- Trial runs with water testing for GSA compliance
- Seal-strength and fill-volume verification
6. Operator Training
The client’s team was trained on:
- Daily start-up, shutdown and CIP cleaning
- Monitoring RO and replacing filters
- Operating the sachet machine and adjusting settings
- Routine maintenance and troubleshooting
7. Results & Return on Investment
The line delivered a stable 2,800 pouches per hour, letting the distributor supply its own channels:
- Stable output: 2,800 pouches/hour with 2 operators
- In-house production improved margins versus reselling
- Consistent quality strengthened the client’s brand
- Secure supply removed dependence on third parties
By capturing the production margin and controlling quality, the distributor improved profitability and recovered its investment within the first year.
Conclusion
This Kumasi project shows how a distributor can move upstream into sachet water production to boost margins and secure supply. From water treatment through automatic filling and packing, zoolinked mechanical delivered a compact, reliable turnkey line tailored to Ghana’s “pure water” market.
Planning Your Own Packaged Drinking Water Plant?
zoolinked mechanical delivers complete sachet, bottle and barrel water lines — from raw water analysis and process design to manufacturing, installation, commissioning and operator training. Tell us your target output, water source and packaging format, and our engineers will prepare a tailored proposal and quotation for your sachet (pouch) water line.
