As gentle as a sommelier

At Veuve Clicquot indulgence sets in before the bottle is even opened. The refined printed label and high-quality glass body make an exquisite first impression.
The presentation of the champagne must not be impaired during automatic cartoning. Gerhard Schubert GmbH in Crailsheim rose to the challenge, supplying the ideal packaging line for this purpose.

The winery, which is located in Rheims (France)  uses Schubert’s system to package 75 cl bottles into two different box sizes: the smaller box contains two cardboard inserts holding three bottles each, while the larger design has room for four inserts.

The system, practically speaking
The TLM system achieves an output of 150 bottles/minute. It replaced a mono-format system with an output of 100 bottles/minute.
The new Schubert packaging line consists of eight sub-machines. It integrates a product belt for the incoming bottles, a transmodule section for the boxes and another section for the carton inserts.
A TLM-F3 robot removes two flat blanks for the carton inserts from the magazine and transfers them to a TLM-F2 which erects them and places them into the size plate of the waiting transmodule. The tool fixes the carton inserts without using glue.
After the TLM-F2 has placed two more carton inserts, the transmodule starts and connects to the other transmodule unit. This unit now moves as a chain whose speed is controlled by the product flow for the "pick-and-place" process. Following the proven counter-directional running principle (opposite running belts) the bottles reach the picker stations from the opposite direction. Photocells detect their position on the product belt. Six four-axle TLM-F4 robots pick up the bottles individually, tilt them 90° horizontally and place them in the carton inserts in the required "head to foot" alignment.

Improved image
The TLM system arranges the bottle formations in the carton insert without using a grouping chain, that often “mistreats” the products. The delicacy of this process differs fundamentally from conventional solutions. It translates to significant advantages in protecting the product.
This is because the mechanical system of a grouping chain stresses the products.
Schubert prevented this potential hazard to the elegant cover by using the TLM-F44 picker stations for Veuve Clicquot.
In addition, the tools of the TLM-F4 are constructed in such a way that the suction surface avoids the label.
There is also no longer any impact or direct contact during the rest of the process to ensure that the champagne leaves the machine as unscathed as it was fed in.

After the picking towards filling
At the end of the picker section, all the carton inserts on the transmodule are loaded with bottles. The transmodule is released from the group and proceeds to the filling station. The products are marked by the laser printer while passing through.
In turn the transmodules  with two boxes come from the opposite direction. (previously erected and placed on the transmodule by a  TLM-F2
Both box sizes contain two layers of carton inserts. During the loading process, two TLM-F2 work at the same time. Each of them grips two cardboard inserts and places them into the boxes. The transmodules join this process individually. That means that the front transmodule already proceeds to be closed while the rear transmodule moves up to the front position and receives a second layer of cardboard inserts. A transmodule with empty cartons moves up to the initial position.
Moving the transmodules one after another in this way is just one of the many possibilities offered by the patented TLM components. Each of the single-axle robots can move on the rail section autonomously. Thus the packaging processes are ideally decoupled, such as for Veuve Clicquot. The example also indicates this because the transmodule makes an even more compact design possible. The system is only 3.0 m wide.

Good cooperation
Satisified with the solution devised by Schubert, Henri,Darré, the winery’s technical director at the Rheims site, enthusiastically stated: «We now package our champagne with higher output and flexibility compared to the past. However, it wasn't necessary for us to accept more complexity to achieve this. On the contrary, the operation, the maintenance... We are very enthusiastic as to the results, and it is a new highlight when we take visitors on our company tour».       

1 1 - The new packaging line for Veuve Clicquot consists of eight sub-machines.

2 - Six four-axle TLM-F4 robots pick up the bottles individually, tilt them by 90° horizontally and place them in the carton inserts. The tools of the TLM-F4 are constructed in such a way that the suction surface avoids the label.

3 - The large of the two box formats contains 12 bottles. 4 - The carton insert with three bottles.

5 - The transmodules on the left transport the boxes, the transmodules in the centre transport the carton inserts and the product belt on the right moves the champagne bottles. 6 - The carton inserts are filled with bottles and placed in the boxes.

The TLM transmodule. Patented, it is a single-axle, rail-based robot. The individual transmodules move autonomously. The rail section can lead through as many sub-machines as desired. There is a turning unit at each end. Unloaded modules return to the other end on a lower track. Energy and data transfer is wireless. Interchangeable size plates are placed on the transport carriages. In this case, they are for the boxes and their carton inserts. Since their introduction in 2009, approximately 1,600 transmodules have been used in TLM packaging machines worldwide.

The protagonists at Reims Veuve Clicquot. «Just one quality - the very best». After the death of her husband, Nicole Clicquot Ponsardin personified this principle and brought great success to the Veuve Clicquot Ponsardin champagne label. The company is now owned by LVMH Moët Hennessy Louis Vuitton (Paris). The Veuve Clicquot vineyards have a perfect location in the Champagne region and spread over 286 hectares. Almost all of the land was purchased by Madame Clicquot herself. Gerhard Schubert GmbH. Prominent medium-sized family business, it is currently employing 900 people worldwide. Schubert builds highly flexible packaging and filling machines, plus thermoforming, filling and closing machines for products of any type from a variety of industries. Packaging any product is easy and manageable using TLM (Top-Loading Machine) systems from Schubert, which also provides a comprehensive service program for its TLM packaging machine systems.