We are currently commissioning a complete edible oil filling line in Poland.
In fact, on the video, you may only see one of two vegetable oil filling lines that make up this whole project.
When completed, this turnkey solution will be able to deliver up to 8000 1l bottles per hour of canola oil (rapeseed oil), both in PET and glass bottles plus 1100 bottles per hour into 5l PET bottles.
Altogether, there are also other bottle formats in the range: 500, 1000, 2000, 3000, 5000, and 10000ml.
Being one of our biggest projects lately, it is very complex – it starts with two blow molding machines (Blueline 6 HiTech & Blueline 1 BIG MAX) with Kaeser compressor room and a glass bottle depalletize at the beginning of the lines.
Later the bottles are transferred to one of two filling monoblocks (Arrow PET/GLASS UNIV 20/6 WeightMatic & Arrow PET 9/3 WeightMatic BIG).
These are proceed by three labellers (STM Mega Roll 9, STM UNO ADE, and PE Labellers Modular SL for rectangular bottles).
After the filling level is checked by inspector, the BIG bottles line has a neck handle applicator and go separately to the palletizing system on Kawasaki robot.
The same palletizing system handles also the wrap-around carton boxes filled with smaller glass and PET bottles. After the palletizing is done, full pallet gets transferred to the rotating arm pallet wrapper Technowrapp, and then gets transferred to the warehouse.
Following previous news, last part of our Pivovara Daruvar Project in Croatia is a complex palletizing system based on two Kawasaki robots.
To recall, the client wanted us to project and implement two complete beer filling lines for aluminum cans and PET bottles by putting them in old building with one existing customer’s line – for returnable glass bottles in cases. We went few steps further, inventing a way that this project would give much more to the investor, and we made a layout that tied the beginning and the end of line with two end-of-lines by STM.
This meant that apart from palletizing packages of cans and PET bottles we were able to offer our client an automatic depalletizing of cases with empty bottles returning to the brewery, as well as palletizing full cases with freshly filled glass beer bottles. Due to the importance of canned beer for our client, we decided to design this system so that the canning line could work independently, using one Kawasaki robot and one gripper, while the PET line could work alternatively with returnable glass line – which was also fine for the client because of having one bright beer tank (BBT) for both these lines. In the end we’ve offered two functions more than expected: depalletizing crates with glass bottles returning to the brewery with capacity of 20000 bph and palletizing cases with full bottles while still being able to meet the required capacities of palletizing can line 15000cph and PET bottle line 3000bph.
A very important matter in this project was also to create a logic of automatic EUR pallet movement inside of the system that has one inlet – during empty bottle crates depalletizing, and needs empty pallets for can palletizing and PET bottle or full crates palletizing. We designed a system with two pallet storages (capacity 15 pallets each), and delivering them exactly where they need to get in the right moment.
Following the commissioning of aluminum can filling line in Pivovara Daruvar, Croatia, we moved to start-up of second complete filling line – into PET bottles.
Client requested a turnkey solution for 3000 bottles per hour at 2l bottle filled with beer. This project was very peculiar because of the need to put our new filling line inside of client’s existing returnable glass bottle filling line. This also required finding a place for a compressor room, as well as designing a way to get through with the air conveyors from the blow molder to the filler’s position.
This filling line consists of a 3-cavity blow molding machine Blueline 3 Standard with a complete compressor room by Kaeser Compressors and MTA chiller. Then there is a big air conveyor buffer that goes into next hall inside of existing line – to the filler’s inlet. Filling machine used is Arrow PET 20/40/8 ISO BEER – our isobaric PET filler for beer, with pre-evacuation of air from the bottle and a high pressure hot water fobber before capping. After the filler, there is a filling level inspector, air knives and an OPP labeller model Uno Roll with CIJ data printer Hitachi.
At the end-of-line, there is a small shrink-wrapping machine AP12, tailored for the capacity of the line – 3000bph packed into 3×2 packages, which gives 10ppm with 120% overspeed. The line ends with package conveyors leading to a complex palletizing system based on two Kawasaki Robots, that we will describe separately.
Our biggest beer filling projects so far starts to come into life as we’ve just commissioned complete beer filling line into aluminum cans with capacity of 15000 cans per hour! This line is just a part of the whole Pivovara Daruvar project in Croatia together with PET filling line and palletizing system.
Like in most of our projects, also in this case we delivered a complete turnkey solution and a wide consulting of client’s needs preceded with an on-site inspection. This was essential because the project is in one of the oldest breweries in Croatia, and there was a lot of hassle to design a layout that will take into consideration existing client’s returnable glass bottle filling line and all of the pipes and media connections that evolved over the years of upgrading the brewery. The bottling line in question starts with an automatic full height, high level can depalletizer and an overturning-rinsing device that takes cans from the high level to the filler level.
Filler used was Arrow CAN 40/6 ISO BEER, with 40 filling valves and a 6-head Zilli&Bellini seamer. After the buffering conveyors, filled cans get into Petek’s pasteurizing tunnel and then to filling level inspector, data coder and air knives to get rid of the water on cans. Further on, the cans get into the Dimac Blue Star shrink-wrapping tunnel that packs cans into 6×4 tray with film or 3×2/2×2 film only packages, with the with the assumption that film only packages are packed in double lane, and then transferred to the palletizing system in double lane as well. Due to the high number of orders, the brewery works with maximum capacity of the filling line for at least two shifts a day filling millions of cans each month since the line was commissioned.
Our client, who already had our equipment for many years decided to expand, and built a new production hall with two complete filling lines, one for smaller bottles from Krones/Kosme and one from STM GROUP. Our filling line is based on all-in-one Synchroblock blow molding-filling-capping machine for 4000bph at 5l still water.
Machine is based on a 4-cavity Blueline 4 Standard BIG blow molder and an Arrow PET 16/6 FlowMatic filler with 16 flow meter filling valves and 6 capping heads. Synchroblock was also given an anti-drip cover with HEPA filters, and a UV lamp for caps placed on caps chute for ensuring the safety of the filled product. Synchroblock is followed by a set of conveyors with additional buffer for emptying the machine in case of line stoppage.
Bottles go through a filling level inspector to the OPP labeller and then follow to a neck handle applicator. After the handle is applied, bottles go to the lane divider changing conveyors from one lane to double lane. Two lanes are essential for the palletizing system to cope with the line’s capacity. 4000 5l bottles per hour can be achieved using a full layer gripper, and by having two pallet stacking places inside the palletizing system. Since the bottle design is demanding (high and unstable bottles), each of the pallet stacking places is also a pallet wrapper, so that there is no need to move pallet full of bottles risking that the bottles will fall off.
When first pallet is full, it starts to be wrapped, and at the same time robot starts palletizing bottles on another pallet at next stacking place while first pallet gets to the warehouse to be picked with a forklift.
We just commissioned our first project in Kyrgyzstan – a complete filling line for up to 9000bph at 1,5l water and drinks, both still and sparkling. The scope of project starts with a 6-cavity Blueline 6 Standard blow molding machine with Ateliers François compressor room and a chiller.
Then there is quite a big buffer at the air conveyors to ensure that there are no stoppages of production.
From the air conveyors the bottles get to Arrow PET 32/54/8 ISO filler that has 32 rinsers, 54 filling valves and 8 capping heads. The machine type is isobaric which enables it to fill both still and sparkling liquids with a stable capacity of 9000bph at 1,5l. After the filler there’s a filling level inspector and a big buffer before the OPP labeller model MegaRoll 9.
At the end-of-line we’ve integrated a Dimac Star One F B.I. for shrink-wrapping. It is worth mentioning, that we also produced a semi-automatic CIP station and a Premix machine model JG6 FlowMix that enables our client to prepare a wide variety of still and sparkling products that are later confectioned using STM GROUP’s line.
Racibórz Brewery dated 1567, located at the same hill with Piast Castle is one of the oldest Polish breweries.
Client wanted to expand their production by starting to fill their beers into aluminum cans and non-returnable glass bottles. The layout of space available for these lines was very small, and thus required a special approach – that is why we suggested a hybrid line. This meant having some of the equipment common for both filling lines (can/glass): one universal depalletizer, then two fillers, and one x-ray filling level inspector, one air knives and one linear self-adhesive labeller, before the packing (that was supplied by client).
Having small space, we also designed quite a big buffer at high level, before cans get into the rinsing-overturning device, and before the bottles reach the vertical conveyor. The line is designed to achieve the capacity of 6000 cans per hour or 3500 bottles per hour, both filling beer in 500ml containers.
Our client decided to order from us our first ever all-in-one machine – Synchroblock, that comprises: blow molding, filling and capping in one machine.
This means much smaller machine’s layout because there is no need for air conveyors between blow molder and filler.
Also, there is no need for the rinsing of bottles, since they get directly from the mold into the filler. However, since the product to be filled was syrup, we integrated all the safety equipment possible, like anti-drip cover with HEPA filters, a UV lamp for caps and a Claranor lamp that disinfects the bottle thread. It’s a very expensive solution, but it’s the best way to disinfect the neck, (which is the only part of bottle that does not heat up in the way through furnace), which leaves no space for the bacteria or germs to be left in the bottle, which is crucial for so sensitive product like syrup that is filled in this Synchroblock.
Browar Kociewski has the smallest beer filling line that we supply – 3500 bottles per hour. This is an entry-level craft brewery capacity for a producer that expands the production into a fully automatic filling machine.
The size of filler and the space needed for an infeed, labeller and outfeed is very small enabling to put the line even into a tiny space. Also, the design of infeed and outfeed may be done according to the client’s needs – either being linear or in a form of a rotative table. Also, this smallest possible line may be expanded with a semi-automatic depalletizer and a bigger infeed table, or a packing machine.
Since 2020 we have built in Poland more than 10 lines of similar size, or bottling machines alone for craft and regional breweries!
One of our newest turnkey solutions we delivered to our clients is a complete filling line for still water with capacity 14000 bottles per hour in Algeria. The line starts with our fastest, 8-cavity blow molding machine Blueline 8 HiTech delivered together with a complete compressor room and a chiller.
After blow molding, the bottles get transferred with a vast amount of air conveyors that serve as a buffer into Arrow PET 40/40/12 NC which is a still product overflow filler. Later the product is buffered at the flat conveyors before getting to the Rolline labeller from PE Labellers that we integrated into our line.
After further buffering, the bottles are packed by Dimac Green Star into film only packages. These are then conveyed by buffering package conveyors into the automatic palletizing system based on Kawasaki robot and a rotative arm pallet wrapper. We also delivered a semi-automatic CIP station which was the last part of equipment for the client to start producing water.