XTS triples cycle rates in packaging technology
High speeds are nothing special in packaging technology. However, if a new system is three to four times faster than previous solutions, then it is definitely worth taking a closer look. However, this is easier said than done with the Tetra Pak® Cap Applicator 40 Speed Hyper. This is because the solution glues caps to beverage cartons so quickly that the human eye can barely keep up. The first user was inspired by this and nicknamed it the "Magic Machine" – and quite aptly too, as the machine has now also won the prestigious Premio Innovazione award.
The fact that the machine achieves up to 30,000 units per hour is due to its unusual design, which has been developed from scratch: the classic drive train is no longer the focus. Instead, the centerpiece is a highly dynamic mechatronics solution based on XTS technology from Beckhoff.
Why is the XTS solution so innovative?
The flexible permanent magnet slides, which allow independent and precise movements along a continuous path, adjust the position of each cap in real time. Two parallel XTS tracks, each 4.5 m long and with 55 individually controllable movers, compensate for the natural differences between the cardboard containers – to an accuracy of a tenth of a millimeter.
XTS thus replaces mechanical components with software logic, increases the degree of digitalization and data transparency, enables condition monitoring, and improves quality assurance. This intelligent, future-oriented approach has been reconfirmed by the Premio Innovazione award, which is presented annually as part of the Italian innovation forum SMAU.
What other added value does the user receive?
A line equipped with the XTS solution can replace three conventional systems. This leads to considerable savings in production space and significantly more operating capacity. At the same time, reliability and efficiency are increased, while downtimes and maintenance work are reduced. It is therefore not surprising that the first installations have taken place at major global players in the F&B industry, demonstrating the revolutionary nature of this technology.
What are the advantages of using XTS at a glance?
- extremely high productivity: up to 30,000 beverage cartons per hour
- high precision: exact positioning and reproducible adhesive application thanks to synchronized XTS movers and image processing
- software-driven flexibility: product changes and format conversions mainly via software, hardly any mechanical conversion required
- parallel operation and synchronization: two XTS lines work absolutely synchronously and can equalize natural differences in the products
- modularity and scalability: adaptation of route length and number of movers with little engineering work for different output classes
- less space required: considerably more output on a smaller footprint compared to conventional production lines
- data transparency and digitalization: central condition monitoring, fast analysis and diagnostic options
- improved quality assurance: real-time monitoring of the adhesive application and automatic corrective measures
- increased availability: significantly increased MTBF thanks to reduced mechanical effort and robust control solution
- seamless integration: complete solution comprising control, motion, I/Os, and HMI with EtherCAT and TwinCAT – components from a single source
- future-proof and expandable: powerful control and motion platform allows for future functional and technological expansions
What does the Premio Innovazione award represent?
The Premio Innovazione is a prestigious award presented annually as part of the SMAU Italian innovation forum. Prizes are awarded to companies and organizations that have successfully implemented pioneering projects - for example through digital transformation, new organizational models or open innovation. As the nomination can only be submitted by users of the respective development, not by the provider itself, the award is regarded as an important instance of best practice in the Italian innovation landscape.
How is Tetra Pak® positioning itself as a machine builder?
As a machine and system engineering company for the food and beverage industry, Tetra Pak® approaches the market with an exceptional combination of process, filling, and packaging expertise. The system provider aims to offer its customers integrated solutions along the entire value chain. Their hallmarks are high automation, energy efficiency and process stability, which helps food producers to reduce operating costs and achieve sustainability goals. Tetra Pak®'s leading position on the market is also built on close cooperation with customers and suppliers. The company sees itself as a reliable plant manufacturer and also as a strategic partner for greater quality, efficiency, and sustainability.