Ronchi Mario SpA: 60 years as a byword for quality in automatic machinery

Since 1966, the Ronchi family name has been synonymous with the world of automatic machinery and with a business philosophy rooted in enthusiasm, research, technological innovation and growth - the guiding principles that have shaped the evolution of Ronchi Mario SpA to this day. Sixty years on from its founding, the third generation at the helm looks to the future with continuity, building on an industrial legacy defined by state-of-the-art quality and ongoing innovation.

EXACTA fillers: versatile quality, user-friendly design

A prime expression of this philosophy is embodied by the EXACTA series of filling machines, representing the latest and most advanced technology in the bottling of both low- and high-viscosity liquid products. Among the standout features of the EXACTA range are flexibility, ease of use, and rapid cleaning and washing, making it a true market benchmark.

Filling accuracy, ease of washing and sterilisation

The EXACTA series filling technology is based on the use of flow meters, either inductive magnetic (for volumetric filling) or mass-type (for weight/mass filling). Both types share a number of characteristics that set the series apart, notably its high filling accuracy (σ = 0.2%). The absence of moving parts within the instruments eliminates all maintenance requirements. In addition, the system is entirely unaffected by electrical, electromagnetic and mechanical interference. The system is further enhanced by the possibility of washing and sterilisation (CIP/SIP) at temperatures up to 130°C.

The EXACTA rotary filler range spans from a minimum of 8 to a maximum of 60 filling valves, meeting a wide variety of production needs with speeds of up to 600 bpm. The EXACTA series machines can be supplied in Monoblock configuration with one or more capping stations, as well as in a large-pitch version suitable for handling large containers of up to 10 litres.

High quality across design, material selection and construction

EXACTA fillers stand out for a number of features that define their high quality in terms of design and construction. From a materials standpoint, the mechanical structure is made of AISI 304 stainless steel, while all parts in direct contact with the product are manufactured in AISI 316/L stainless steel. In terms of architecture, the EXACTA system features no bulk product tank installed on board the machine, a reduced product volume inside the filler, and the possibility of direct feeding from storage reservoirs. The feeding system operates in a closed circuit, eliminating any risk of contamination from air or atmospheric agents. Furthermore, the design prevents any product spillage during the filling phase.

Ease of cleaning and format changeover

From a maintenance perspective, cleaning (CIP) and sterilisation (SIP) are carried out efficiently and rapidly, without the use of spray balls or the need to dismantle components. Washing and sterilisation operations are fully automatic and programmable via the operator panel. The washing solution can be recovered either through an automatically inserted tray or via a closed-circuit system. Bottle format changeovers are also extremely quick and straightforward, thanks to the absence of gripping systems to hold the bottle.

Process control: sensors and digitalisation

The control systems installed on EXACTA fillers ensure correct filling of every bottle. In the event of out-of-tolerance filling, bottles are rejected and diverted onto a parallel discharge conveyor. Flow meters and all filling operations are managed by a standard PLC installed on board the machine. All motors are variable speed, controlled by inverters and programmable via the operator panel. The machine is also equipped with a hardware and software package for product feed pump control (P.I.D.).

The SIRIO capping range

Ronchi’s portfolio also includes the SIRIO capping systems, covering a wide range of applications and closure types across sectors such as personal care, detergents, pharmaceuticals and food. Machine robustness is ensured by an AISI 304 stainless steel structure, while speeds of up to 600 bpm are achieved through rotary turrets with 4 to 30 capping heads. These systems can integrate multiple turrets onto a single base-frame in Monoblock configuration for the application of different types of closures onto the same container.

A range designed for every requirement

SIRIO cappers can be configured for handling corrosive products, using special metals or alloys such as titanium, Hastelloy, Duplex or Super Duplex, selected according to the specific product characteristics. The range also includes the explosion-proof version suitable for installation in classified hazardous areas (ATEX or UL), as well as large-pitch machines for large containers.

Reliability from changeover to control

In all SIRIO capping systems, components required for bottle and cap format changeovers are equipped with quick-release devices and can be replaced without tools. Control systems ensure correct cap positioning onto the bottles. In the case of missing or unseated caps, bottles are rejected and diverted onto a parallel conveyor. Caps are fed via automatic rotary mechanical sorters, while transfer from sorter to capper is achieved through horizontal air-cushion cap tracks or motorised conveyors. Guide adjustment for different cap sizes can be controlled through a centralised device. The range also includes cap elevators with hoppers of varying capacities, ensuring different levels of feeding autonomy. All SIRIO cappers can be supplied as standalone units or integrated with EXACTA fillers.

Unscrambling and orientation with BETEL Delta EVO

Ronchi solutions are used worldwide by leading players in sectors ranging from beauty and personal care to pharmaceuticals and food. Among its flagship models is the BETEL Delta EVO bottle unscrambler, designed to feed the packaging line with both symmetrical and asymmetrical bottles. This modular machine can be equipped with 1 to 6 Delta robots and operates at speeds of up to 400 bpm. It can feed symmetrical or asymmetrical bottles, either in pucks or directly on the line conveyor. BETEL Delta EVO ensures rapid format changeover and ease of use, thanks to an intuitive HMI that also enables historical data collection.

Robotic, modular, versatile

Delta robots, programmed to handle bottles of any shape and size, can also perform bottle orientation, eliminating the need for a separate orienting machine. Bottles can be placed into pucks or directly on the line conveyor. The modular concept allows the system to meet specific production speed requirements with the possibility of 1 to 6 robots for speeds up to 400 bpm. A U-shaped bottle conveyor system ensures continuous supply and return. Fast format changeover, achieved simply by selecting a recipe, represents the ideal combination of flexibility and efficiency, eliminating the need for additional sets of bottle change parts for different formats. Changeover speed is further enhanced by an automatic emptying cycle that clears the circuit of the current bottle format and prepares it for the next. The main electrical cabinet is made of stainless steel and is mounted on board the machine to reduce footprint and eliminate the need for wireways.