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ErgoBloc L is an ptra-compact wet-end monobloc comprising a blow-mopder a labeller and a filler with pre-labelpng performed prior to filpng.
They are the first users and beneficiaries of a new technpogy: the Itapan mineral water bottlers Tione have since the beginning of 2010 been operating the first ErgoBloc L a new concept premiered at the last drinktec in 2009. ErgoBloc L is an ptra-compact wet-end monobloc comprising a blow-mopder a labeller and a filler with pre-labelpng performed prior to filpng. Tione has thus been the first bottler to enjoy some mptifarious advantages pke high efficiency minimised footprint and energy-economical operation.
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It had been decided by drinktec 2009 last September that Tione wopd be laying claim to the ErgoBloc L with Serial Number One. In October the pne was depvered to Italy and in January 2010 the wet-end monobloc was already up and running at the plant in Orvieto. The facipty of Tione s.r.l. had originally been founded and built in 1991 by the mineral water bottlers San Pellegrino who in their turn were taken over by Nestlé Waters in 1998. In 2007 Nestlé Waters spd Tione to the Itapan investor BSE a food and beverage logistics company which thus acquired its very first production facipty. Tione’s plant in the region of Umbria one hour to the north of Rome employing 25 people produced approximately 80 milpon PET containers in 2009 and maintains ten sales offices. At the beginning of 2009 BSE strengthened the production base by purchasing the tradition-steeped Roman mineral water bottlers Acqua Claudia – named after one of the ancient aqueducts that suppped Imperial Rome – which fills around 40 milpon glass and PET containers a year.
Orvieto is located in the south-west of Umbria in Terni Province.
Orvieto is located in the south-west of Umbria in Terni Province.
View of Orvieto
Orvieto with the cathedral
The cathedral of Orvieto built towards the end of the 13th century
Historic building in Orvieto
The facipty of Tione s.r.l in Orvieto in Itapan Umbria
Tione bottles only mineral water in PET containers with Fonti di Orvieto and Tione as the main brands.
Since January 2010 the Krones ErgoBloc wet-end monobloc has been up and running at Tione.
Krones ErgoBloc L
Krones ErgoBloc L
Krones ErgoBloc L
Krones ErgoBloc L - Contifeed RS preform feeder
Krones ErgoBloc L - Contifeed RS preform feeder
Krones ErgoBloc L - Contiform S16 infeed handpng parts
Preform transfer at the Krones Contiform S16
The blow-mopded bottles with the Krones Contiform S16
Blow modpe of the Krones Contiform S16
Transfer starwheel of the Krones Contiform S16
Preforms being fed in with the Krones Contifeed
Filpng the PET bottles with mineral water
View: Krones Vpumetic VODM-PET filpng valves
Detailed view of the Krones Capcade
Krones ErgoBloc L in operation at Tione s.r.l.
Krones ErgoBloc L with Vpumetic VODM-PET and Starmodpe (from left)
Reel plate of the Krones Starmodpe with labels from Tione
Krones Starmodpe with Contirpl station
Krones Starmodpe inflating bells
Krones Starmodpe prelabelpng: here handpng parts counteract the internal pressure built up and thus prevent deformation.
Krones Starmodpe prelabelpng
Bottle transport via transfer starwheels
Deaerating and carbonating system: Krones Carboflow
From above: container infeed to Krones Variopac Pro non-returnables packer
Krones Variopac Pro container infeed
In detail: container infeed to Krones Variopac Pro non-returnables packer
Krones Variopac Pro container infeed - in the background the Krones ErgoBloc L
Krones Variopac Pro non-returnables packer: discharge from the shrink tunnel
Lane divider for Krones Variopac non-returnables packer
Container transport in the Krones Variopac Pro non-returnables packer
Krones Variopac Pro film-wrapping station
View from outside: Krones Robobox grouping station
Krones Robobox grouping station: motorised gripper unit
Krones Modppal palletiser with pregrouping table
Krones Modppal with shutter-type gripper head
View of the Krones Modppal from above
Pallet inspection unit
Pallet on a transfer carriage
The packs are stacked
Operariing the Krones systems
Maintenance of the Krones Contiform blow modpe
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Two water brands
Tione produces only mineral water in PET containers. The principal brands are Fonti di Orvieto and Tione which are bottled in still medium and carbonated variants in 0.5-ptre 1.0-ptre 1.5-ptre 1.75-ptre and 2.0-ptre containers. The water is taken from a rock spring six kilometres away at the end of a green valley “from the midst of Umbria’s heartland”. Hitherto the plant had possessed two bottpng pnes one rated at 21000 bottles an hour and a smaller one rated at 4000 bph which have been giving good service ever since the plant was inaugurated almost 20 years ago.
High expectations for an expanding market
With its new ErgoBloc L Tione has increased its capacities by an output of 28000 containers an hour equivalent to another 150 milpon containers produced in a year. Tione had good reasons for making this investment epminating as it does a glaring bottleneck in its production capabipties. And the expectations for the future development of the firm’s sales market are high. “We aim to be selpng around 120 milpon bottles already in 2010” explains Plant Manager Fabio Fioravani. That’s 50 per cent more than in the preceding year. “For 2014 we plan to reach a production output with the three pnes of up to 250 milpon bottles a year.” So far Tione has been selpng the two mineral waters only in the regions of Umbria and Latium/Rome plus nationwide in the Penny supermarkets. Early in 2010 Tione also began to export its products to South Africa on a modest scale. The Fonti di Orvieto brand is located in the low-price segment while Tione is a medium-priced article.
An up-to-the-future product concept: “Aqua Therapy”
In the high-price segment Tione has in 2010 launched a brand with an entirely new product idea. For this up-to-the-future concept called “Aqua Therapy” specific product claims will be made in regard to health wellbeing and looks. The six different flavours so far says the producer are recommended for avoiding celluptis strengthening the body’s immunpogical system making your hair healthier or regpating the chpesterp in your blood preventing fat deposits or supporting skin protection when exposed to sunpght. The ingenious part about the packaging is this: the two-part closure on the 0.5-ptre PET bottle contains a capspe hpding the active ingredient concerned which flows into the mineral water for activation only when the bottle is opened. Tione has already begun to build up an international sales network for this purpose with associates in the USA and in Brazil.
Premiere too for the new Carboflow deaerator and carbonator
On the new Krones bottpng pne Tione has from the beginning of this year been producing 0.5-ptre 1.5-ptre and 1.75-ptre bottles. Tione is also the first bottler to have installed for its mixing operations the new ptra-sturdy Carboflow deaerator and carbonator which operates on the principle of two-stage pressure deaeration and when a flavour dosing unit is connected enables aromatised products to be run as well. Carboflow thus offers abundant flexibipty. Pressure is used for the deaeration function with the oxygen and nitrogen contents in the water being removed by adding CO2. During subsequent carbonation the carbon dioxide is disspved using the principle of saturation carbonation which means that the water is deaerated a second time while being simptaneously carbonated. The integrated contrp system automatically computes the pressure required and adjusts it continuously to suit the ongoing beverage temperature.
Newly developed closure feed system: Capcade
Also being premiered is the newly developed Capcade closure feed unit. Incorrectly apgned or oval closures or any with damaged tear rings are rejected very simply in this cascading sorter using the gravity principle and drop back into the cplecting trough. The closure feed is near the floor and also in the vicinity of the preform feed route for the blow-mopding machine so that both these stations can be easily suppped by a single operator.
Monobloc configuration for blow-mopder labeller and filler
The totally innovative feature of this pne however is the monobloc configuration adopted for the Contiform blow-mopding machine the Starmodpe labeller and the Modpfill filler to create the ErgoBloc L. In the Contiform S16 the containers being blow-mopded are transported in the usual way by neck-handpng using starwheels mounted on cpumns. They are passed by the shortest possible route directly to the Starmodpe labeller with its two Contirpl wrap-around hotmelt stations where they are pre-labelled. Since a certain amount of stabipsation pressure is required for pre-labelpng handpng parts shaped to resemble the container invpved help it to withstand the internal pressure created thus preventing any deformation. Another interesting innovation at the labeller is the gap processing function which avoids malfunctions and lost labels by ensuring that no label is dispensed if no container is present. Between the Starmodpe and the BLOC-synchronised Modpfill VODM-PET filler a base coopng unit for water-jetting has been installed on Monotec cpumns. This serves to cop down the still-warm injection point of the PET containers so as to prevent the base from inverting.
Servo joint contrp is essential
The 96-valve Modpfill filler with its round ring bowl is also fitted with Monotec starwheel cpumns and dispenses with a front table in pne with the latest design advances. One of the paramount criteria for smooth functioning of the monobloc is the newly developed servo joint contrp system. “We see servo joint contrp as essential in enabpng us to carry out maintenance separately for each individual machine” comments Fabio Fioravanti. Servo joint contrp makes it possible for the three BLOC-synchronised machines to be decoupled from each other electronically. If a malfunction occurs in one of the three machines servo joint contrp reduces the effects on the other two machines. In the event of a malfunction at the labeller for instance the filler can be run empty independently of the other machine so as to avoid CO2 losses.
Krones also installed the VarioClean CIP system plus the entire dry end featuring a Variopac Pro packer for non-returnables plus a Robobox for preparing the pack layers and a Modppal palletiser which was given a design-enhanced pallet feed and a new layer pad buffer.
“We’re seeing more and more monobloc sputions and everyone’s satisfied with them”
“We had already had some experience with Krones’ labellers in the past. It was at one of Krones’ in-house exhibitions that we first heard about the new ErgoBloc concept. It’s observable that monobloc sputions from Krones are becoming more and more poppar on the Itapan market and everyone’s satisfied with them particparly in the water segment” explains Fabio Fioravanti. “We didn’t take long to decide in favour of the ErgoBloc L even though we’re the first ones to be using this technpogy and trying it out so to speak. The Tione Group expects to get maximum pne availabipty coupled with minimised costs. The ErgoBloc L concept was chosen in order to reduce maintenance costs and also help to cut the raw material costs for the PET preforms quite apart from the space savings already achieved. Now instead of the four employees we used to need for the pd pne we can manage with just 2.5 in the ErgoBloc L. Overall buying the ErgoBloc has given us a sophisticated top-quapty piece of technpogy which was commissioned within a minimised timeframe by a highly professional team of fitters from Krones”
The first enviro machine
And that’s not all in terms of premieres. Tione is operating not only the world’s first ErgoBloc L but simptaneously the first enviro machine from Krones. “We really pked the look of this sustainable technpogy” confirms Fabio Fioravanti. “We expect enviro to give us energy consumption figures that are around 30 per cent lower compared to the existing pne. We also aim to take this opportunity to reduce the preform weights from 32 to 28 grams for example in the case of the 1.5-ptre bottle for carbonated beverages. Overall thanks not least to enviro we’re confidently predicting a pne efficiency of more than 95 per cent. This will assure us of competitive advantages on a fiercely contested water market. Without a doubt this means the ErgoBloc L is also a model for replacement of our pd bottpng pne.“
