Liquid Primary Packing

Fameccanica Fameccanica created its first liquid filling line in 2012, at the request of a leading multinational company looking for a partner that would enable it to achieve a technological breakthrough. The result of this operation is the BVG technology that combines the skills and experience gained in the construction of diaper as well as dosing and packaging machines.

According to the specific requests of the multinational, the line had to have a higher production speed, a greater degree of flexibility, occupy less space, integrating the bottle unscrambler, the label maker, the filler and the capper in one “superblock”; it had to cost less and allow for a 50% cut in format change time.
«We signed the supply contract, and managed, right from the construction of the first line, to fulfil all the demands, reducing the customer’s total cost of ownership», recalls Rocco Amicone.

FROM LARGE TO SMALL
The current range of machines, all fully integrated, unbuffered and easy to install, comprises three rotary and two linear models. Designed starting from the top speed version, hence with performance to be scaled down, they appear to have drawn a lot of interest because they respond to various user demands. There are two platforms: one for personal care, for containers to 1,000 ml, and one for home care, for containers to 3,000 ml.

LPP3. The first machine to be built was a direct evolution of the first platform to be made. A highly compact modular monoblock that is “mechatronic”, as in the best company tradition, with servo motors to replace the traditional mechanical functions, simplified wiring, user-friendly man-machine interface, positive handling of the bottles to prevent scratches, and intelligent solutions for a fast format change. Capable of filling, capping and labelling containers for liquid products speeds of up to 400 bottles per minute, with a high yield and minimal waste, it represents the top of the range: robotic bottle unscrambler, full servo labeller, filler with flowmeters, universal capper...
 
LPP2. Created from a downsizing of the main platform, this is a medium-to-high-speed machine: up to 300 bottles per minute. This model enjoyed immediate success, so much so that two for the personal care and two for the homecare segments have already been sold.

LPP1 e LPPi.  But there is more. In order to cater for customers with lesser spending power and greater need for flexibility, Fameccanica have planned another two machines to complete the range. The LPP1, a small fully servo rotary machine with speeds up to 200 bottles per minute. Lastly the LPPi, with linear speeds of up to 100 bottles per minute. The LPPi is the entry level of the LPP range and is characterized by a high flexibility and a very attractive price, while sharing the same high-end technology of the rotary machines.

WATCHWORD: DO BETTER

Below the key innovative features of the range.

The modular robotic bottle unscrambler is indeed the element that makes the difference on the market. Tens of types have been produced, intended for different situations around the world, often to replace rotary sorters, with the aim of improving line productivity.
Its strength lies in its zeroing of changeover times.
There is no need to manually replace any mechanical parts, no equipment costs (starwheels, selectors, etc.), all one need do is to key in or call up the bottle data on the computer and the machine is ready to start: in just  1 minute.

Important notes on the costs: according to Giallombardo’s estimates, against conventional unscramblers, the average payback time is two years.

Rotary filling machine with magnetic or mass flowmeter dosing system: the Fameccanica patented filling valve guarantees a duration of more than 2 million cycles and an exceptional filling accuracy. For customers who assembled valves from other manufacturers, Fameccanica can offer a technology upgrade.

Universal rotary capper, with electronic cam, for dealing with any type of closure. Application flexibility and accuracy of positioning and closing torque are guaranteed by the full servo system, while a sophisticated vision system intercepts and discards defective closures.

Servomotor driven rotary labeling machine for maximum accuracy and total control; the individual containers can also be axially oriented during the labeling process, obtaining the best possible result without having to use devices such as smoothing brushes (normally subject to wear and difficult to adjust).

THE CUSTOMERS’ THANKYOU
Fameccanica, to date, has installed several dozen LPP machines around the world (complete lines and stand alone machines).
«The first LPP3 line, installed in China - Giallombardo underlines with satisfaction - has a customer measured production efficiency of more than 95%».
The feedback resulting from the last LPP3 line installed in the United States (one of the most technologically advanced plants in the world) has also been highly positive; Giallombardo tells me he called for a meeting with the customer, having had no more news from him after installation took place in October 2016: «Indeed, the production manager told me that the Fameccanica line is the one that presents the highest performance throughout the facilities and is preferred by operators because it is the easiest to use».
The customer declares an average format change of less than 30 minutes (liquid, bottle, label and cap) with two operators, including washout.
The last two LPP2s recently delivered to a Chinese customer have also drawn successful feedback.

EASY LIFE, IT'S ALL IN THE NAME Many user companies in recent years seem to have suffered a drop in technical skills: At times even the engineering sections are affected by this trend, but that more often relates to all personnel involved in the production lines, where use is often made of temporary, scantily trained workers. Fameccanica has its own response to this trend, primarily by offering extremely sophisticated machines, that though are simple to use, with automatic adjustments controlled by servomotors where possible, and simple, ergonomic manual settings that are repeatable without having to resort to tools. In addition, however, Fameccanica also offers Easylife. «It is an Industry 4.0 application designed in collaboration with Microsoft Italy - explains Mario di Donna - allowing all line data to be registered on the cloud, this being the efficiency, reject and servomotor operating data, as well as the cause of stoppages, and to organize the same intelligently and intelligibly with appropriate algorithms». The first line equipped with Easylife is a production line for diapers; the next will be a detergent filling line, and is currently under construction. Easylife is also an extremely effective tool for tele-assistance. If the customer so wishes and complies, Fameccanica technicians can use the remote telemetry to make a fast, accurate diagnosis without additional costs to the customer. Among other things Easylife allows the carrying out of preventive and predictive maintenance. Hence, when it comes down to it, Easylife is proposed as a tool to get the max. performance from ones system in a simple, intuitive, cloud-based manner and with minimal investment.

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