Aseptic carton filling machines: the choice between mechanical and mechatronic solutions

14 April 2020

Contents of the article

1. MECHANICAL AND MECHATRONIC SOLUTIONS FOR ASEPTIC CARTON PACKAGING

2. ADVANTAGES AND DISADVANTAGES OF THE DIFFERENT TECHNOLOGICAL SOLUTIONS FOR ASEPTIC CARTON PACKAGING

3. CONCLUSIONS ON THE COMPARISON BETWEEN THE TWO DIFFERENT PACKAGING SYSTEMS

The modern industry is demanding few essential characteristics: performance, reliability, and low operating costs. These are indispensable requisites for all technologies used in the various sectors of the market. Moreover, the need for flexibility is increasing both in terms of the new products to be launched on the market and of reduction of their launch times.

Companies production also requires switching from one type of packaging to another in the shortest possible time, without the assistance of highly qualified technical personnel.

Let's examine the requirements that filling machines have to meet in terms of aseptic carton packaging.

On one hand, the producers of milk, beverages, and liquid foods require machines that can provide maximum reliability; on the other hand, they require solutions that can deliver increasing levels of flexibility. Examples of this, are machines that can switch from one package shape to another that have the same or a different cross-section.

Mechanical and mechatronic solutions for aseptic carton packaging

Aseptic carton filling machines can be made using mechatronic design solutions (or electronic, with the extensive use of servomotors) or using mechanical solutions (characterised by a mechanical changeover system).
In light of the requirements outlined above, it is perhaps useful to provide an overview of the two solutions so that companies that intend to use aseptic filling machines for packaging products (such as UHT milk, juices, wine, and other liquid foods) in multilayer cartons can make the best choice when purchasing an aseptic filling machine based on their requirements and the characteristics of their company.

It should be clarified that aseptic packaging technology is mainly based on two concepts: packaging integrity and aseptic filling.

The choice between a mechanical or mechatronic solution has no impact on the aseptic process of the multilayer carton filling machine.

Advantages and disadvantages of the different technological solutions for aseptic carton packaging

To understand this more clearly, we will examine the characteristics of the two systems in detail.

The pros and cons of an aseptic filling machine based on a mechatronic drive system

A servomotor drive is intrinsically flexible in as much that it allows you to change the motion laws via software without having to make modifications to the machine. It is therefore fast to implement as the operator only has to select the appropriate configuration from the panel. This is a useful feature if you need to launch a new product on the market because some of the changes are simplified, resulting in time savings and lower costs. Modification to the motion laws using mechatronic technologies can be implemented in all formats used by the filling machine. Moreover, there is no limit to the number of motion laws that can be implemented, and this can be done at any time.

On the other hand, a critical issue related to solutions based on mechatronic drives is that the problems linked to the servomotors are also automation related and therefore require the intervention of a software specialist. It is often impossible for operators and maintenance technicians who are not specialised in the field of automation, to overcome these problems quickly. A minor electronic fault can become a serious problem and result in unscheduled downtime.

In aseptic packaging, the objective, in terms of brick filling precision (volume of edible liquid in ml), is to comply with a tolerance of 1 per thousand. In this respect, the precision that can be achieved by electronic systems has limitations depending on the speed.
This limitation of mechatronic solutions is accentuated when the weight and inertia of the components increase. This is an extremely important aspect for the aseptic carton packaging sector because the integrity of the package depends on the precision of the mechanical settings in specific machine units. Mechatronic solutions typically use belts that may deform during use. This can indirectly cause variations in the mechanical settings: sometimes, this can lead to issues regarding packaging integrity.

Systems based on electronic technologies tend to be more sensitive to power surges in the production facility. This could increase the risk of mechanical failure and should not be underestimated, especially in facilities located in countries in which infrastructure is poor.

Aseptic carton filling machines: the choice between mechanical and mechatronic solutions

The pros and cons of an aseptic filling machine based on a mechanical drive system

Generally speaking, a cam can guarantee absolute precision even at high speed, especially in the case of desmo cam systems that do not permit mechanical play between the components. The repeatability of performance over time is guaranteed and constant, especially if the cam unit is located in a protected and adequately lubricated environment.

Unlike a mechatronic drive system, which in many applications is used in conjunction with belts, cams are less susceptible to problems related to component wear and the possible consequent variations to the mechanical settings. The cam systems are not particularly sensitive to the weights involved, especially at high speeds, as long as the cams are the correct size.

The risk of mechanical failure due to power surges is low because there are fewer electronic components. This obviously has a positive impact in terms of reliability as the movements are mechanically linked together and there is no risk of collision, which would cause costly downtime for the customer.

It is easier, faster, and less expensive to solve technical issues in a mechanical system. In contrast to systems that use servomotors, troubleshooting is more intuitive and does not require the intervention of highly specialised technicians.

In terms of flexibility, from a design point of view, implementing a mechanical solution for changing the format using cams via the operator panel is complex. It would require incredibly advanced mechanical design skills that are rarely available. Although extremely advanced and sophisticated technological design solutions are required, cam mechanisms guarantee greater reliability over time in terms of system robustness and therefore provide better production efficiency.
Contrary to what you might think, mechanical drive systems also allow you to efficiently manage various aspects of flexibility.
First of all, thanks to this solution, it is possible to quickly switch from one package to another having the same cross-section (e.g. change from a square 500 ml package to a square 1000 ml package in just a few minutes, without loss of sterility).
It is possible to switch from one product to another (3D conversion) having a different cross-section, for example from a 200 ml Slim package to a 1000 ml square brick, within a reasonable amount of time, using company personnel (therefore without needing the assistance of the machine manufacturers’ technicians).
Finally, it is possible to use packages having special and personalised shapes on the same machine. Innovative technical solutions mean that the packaging machine is designed to form packages that have not yet been designed i.e. the characteristics (shape and size) of which are not known at the time the machine is purchased. This allows the customer to request a modification to the package format at a later date, according to his marketing requirements.

The mechanical format changeover solution has a higher cost compared to the mechatronic solution because the system needs additional high technological content mechanical units, which are not necessary if a mechatronic system is used. So, basically, you require a cam and an additional mechanical changeover system.

The complexity of the design and the higher costs are justified by the increased reliability, efficiency, and precision.
To summarise: compared to a mechatronic system, a mechanical solution offers greater robustness and significantly higher performance.

Although it is important to underline that these solutions, when applied to the format changeover system, require the use of multiple cam units, in actual production systems there is no need for solutions that require a higher number of format changes. Essentially, the normal production needs of a company can be satisfied using 3 cams.

Conclusions on the comparison between the two different packaging systems

Despite their higher cost and complexity, for aseptic carton packaging where very high levels of performance and reliability are required, mechanical solutions are preferably for packaging systems that allow format changes.
The characteristics of this technological solution, previously discussed in detail, make technical interventions during production runs faster and more streamlined. This guarantees overall advantages in terms of productivity and therefore Total Cost of Ownership (TCO).

IPI has extensive expertise in the implementation of mechanical packaging solutions for many different industries, such as the food and beverage one. The result of this expertise is the FX120 aseptic filling machine: this is the fastest flexible roll-fed aseptic filling machine in the world.

The FX120 combines the strengths of the mechanical transmission systems, a high production capacity and flexibility.

If you would like to receive further information about the FX120 filling machine and other solutions designed by IPI for you, please contact our experts:

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Consent to personal data processing with regard to the purpose specified under the letter e) of article 4 of the Privacy Policy below

(“Privacy Policy”)
Version May 2023

SUMMARY

1. INTRODUCTION
2. CONTROLLER AND CONTACT DETAILS
3. DATA SUBJECTS
4. PURPOSE OF PROCESSING, CATEGORIES OF DATA AND LEGAL BASIS
5. DATA RETENTION PERIOD
6. OPTIONAL/MANDATORY PROVISION OF PERSONAL DATA
7. PERSONS ACTING UNDER THE AUTHORITY OF THE CONTROLLER AND OTHER RECIPIENTS
8. TRANSFER OF DATA TO THIRD COUNTRIES (EXTRA EU OR EEA)
9. RIGHTS OF THE DATA SUBJECT
10. RIGHT TO OBJECT
11. COMPLAINT

1. INTRODUCTION

This Privacy Policy, in accordance with the General Data Protection Regulation (EU) 2016/679 on the protection of natural persons with regard to the processing of personal data(“GDPR”), aims at providing our customers and suppliers (also potential ones) with all the information related to the processing of their personal data (“Data”) carried out in order to enter into, manage and terminate contractual relationships with IPI S.r.l.

2. CONTROLLER AND CONTACT DETAILS

IPI S.r.l. (“IPI”), with registered office in Italy, San Sisto (ZIP 06132 - PG), Via Giuseppe Piermarini n.19;

website: https://www.ipi-srl.com/it (“Sito”);
email: privacy@ipi-srl.com;
phone number: + 39 075 528521.

3. DATA SUBJECTS

Natural persons who establish relationships with IPI as:

Customers, also potential ones;
Suppliers, also potential ones (e.g., consultants, contractors and sub-contractors);
Representatives/Contact persons of legal persons (e.g., of customers, contractors and sub-contractors);
Personnel of Suppliers;

4. PURPOSE OF PROCESSING, CATEGORIES OF DATA AND LEGAL BASIS

PURPOSES OF PROCESSING:	CATEGORIES OF DATA:	LEGAL BASIS:
a. to enter into and perform contractual relationships with Customers and Suppliers (also potential ones), as well as to comply with the related legal obligations (for instance, the obligations provided for by the law concerning the protection of health and safety in the workplace (as per Legislative Decree 81/2008), with particular reference to the assessment of the technical/administrative suitability of Suppliers).	- *- data collected through the contact form* available on the Website - data concerning the assessment of financial reliability -identification data (name and surname, tax code); - contact data (phone number, email/certified email and address); - data concerning professional qualifications and working/job positions; - billing data(VAT, business/company name) - payment data (for instance, bank account details or details related to credit cards); - data obtained in the context of technical interventions, including evolutionary maintenance**.	- performance of contractual obligations or pre-contractual requests (article 6.1.b. GDPR); - compliance with a legal obligation (article 6.1.c. GDPR)
b. to verify that Personnel of Suppliers hold the necessary qualifications and certificates showing the suitability for carrying out certain activities/jobs, as required by the by the laws concerning the protection of health and safety in the workplace and to verify the regularity of fulfilment of remuneration, social security contribution as well as regularity of fulfilment of insurance and/or fiscal obligations and however the compliance with legal obligations by contractors and sub-contractors, also with a view to protecting IPI having regard to its joint liability.	- identification data of Personnel of Suppliers - data concerning qualifications and working/job positions related to Personnel of Suppliers; - data concerning remuneration, social security contribution, insurance and/or fiscal aspects related to Personnel of Suppliers; - data concerning professional qualifications and skills to carry out certain jobs/activities related to Suppliers and Personnel of Suppliers.	As regards to common data: - compliance with a legal obligation (article 6.1.c. GDPR); - legitimate interest of the controller (article 6.1.f. GDPR). As regards to special categories of data (health data): - - carrying out the obligations and exercising specific rights of the controller or of the data subject in the field of employment and social security and social protection law (article 9.2.b GDPR); - reasons of substantial public interest (article 9.2.g GDPR).
c. to verify and check the absence of any conduct that could represent as potentially or actually a crime under the Italian Legislative Decree n. 231/2001 concerning the corporate liability, as well as to verify the absence of potential related risks (e.g., criminal convictions and/or disqualifications measures referred to Suppliers).	- data already processed by IPI by virtue of existing relationships with Customers and Suppliers (also potential or former ones); - further data collected by IPI as a consequence of controls, inspections and/or audits to the extent permitted by law.	As regards to common data: - legitimate interest of the controller (article 6.1.f. GDPR); - purposes compatible with the purpose for which personal data have been collected (article 6.4. GDPR). As regards to special categories of data: - - reasons of substantial public interest(article 9.2.g GDPR). As regards to data relating to criminal convictions and offencesthe processing is carried out in accordance with the provisions set forth in article 10 GDPR and article 2-octies of the Italian Legislative Decree n.196/2003.
d. except where the right of objection has been exercised by Customers(“Opt-out”, see paragraph 10 of the Privacy Policy), to send - within the framework of a previous sale of a product or service - general informational, promotional and advertising communications concerning the goods and/or services provided by IPI or the corporate group of which IPI is part similar to the ones previously purchased by the Customers (c.d. “Soft Spam”).	- email address of Customers and/or the relevant Representatives/Contact persons.	- - legitimate interest of the controller (article 6.1.f. GDPR).
e. to send marketing, promotional and adverting communications and materials concerning the products and/or services provided by IPI or by the corporate group of which IPI is part.	- contact data(name and surname); - -Company of belonging and related Country; - email address of Customers and/or the relevant Representatives/Contact persons; - phone number of Customers and/or the relevant Representatives/Contact persons; - *data collected through the contact form* available on the Website,** whenever the data subject has given its consent to the processing of its data for marketing purposes.	- consent(article 6.1.a GDPR).

5. DATA RETENTION PERIOD

Data of Suppliers, Customers and the related Representatives/Contact persons and Data of Personnel of Suppliers are processed by IPI for the entire duration of the contractual relationship and, without prejudice to Data that must be retained to comply with legal obligations (e.g. invoices, transport/shipping documents and other documents required for the accounting records), are erased after the termination of the contractual relationship, once expired the periods of limitation from time to time applicable, as provided by the applicable law, usually corresponding to ten years from the termination of the relationship.

Data of Personnel of Suppliers, processed by IPI by virtue of its joint liability as required by law, are retained until the expiration of the joint liability period pertaining to IPI and/or the related periods of limitation as established by the applicable laws.

In order to pursue the purposes related to fulfilment of legal obligations concerning the protection of health and safety in the workplace regarding the assessment of suitability of contractors/sub-contractors (paragraph 4a of the Privacy Policy) and verifications of Personnel of Suppliers (paragraph 4b of the Privacy Policy), IPI – as a mean of the processing activities - relies on a supplier portal.

Data processed for the purposes of verifications, controls and/or inspections carried out under the scope of the Italian Legislative Decree n. 231/2001 are retained for no longer than it is necessary in order to perform the related activities and are erased once expired the period of limitation set forth by the applicable law, usually corresponding to five years, without prejudice to reports made by the Supervisory Committee of IPI as a consequence of verifications, controls and/or inspection activities.

The above-mentioned data retention criteria/periods could be extended in the event a lawsuit has been filed before courts/ judicial authorities or in the event of any out-of-court negotiations/settlements. In such cases, Data shall be processed until the dispute has been settled.

Data processed for Soft Spam purpose (paragraph 4d of the Privacy Policy) are processed until the Customers’ exercise of the right to object Opt-out and, in any case, such data are erased once the term of 24 (twenty-four) months has elapsed from the previous commercial relationships with IPI.

Data of Customers and/or the Representatives/Contact persons which are processed for marketing purposes (paragraph 4e of the Privacy Policy) are processed until withdrawal of the related consent, provided however that such data are erased after 24 (twenty-four) months, unless a consent renewal is collected or the Data are anonymized.

6. OPTIONAL/MANDATORY PROVISION OF PERSONAL DATA

Except for the purpose described in point 4e, in relation to which the provision of Data is optional and the related consent can be withdrawn at any time, the provision of Data is essential to IPI in order to comply with legal obligations to which IPI is subject as well as to fulfil its contractual obligations or to take steps at the request of data subjects prior to entering into a contract. The failure of providing such Data, wholly or partially, will prevent IPI from replying to the above-mentioned requests, to perform its contractual obligations and/or to comply with the relevant legal obligations.

7. PERSONS ACTING UNDER THE AUTHORITY OF THE CONTROLLER AND OTHER RECIPIENTS

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b) external recipients(also including other suppliers), belonging to the following categories (i) entities/persons performing shipping and/or delivery activities of IPI’s products; (ii) parent company and other companies belonging to the corporate group of which IPI is part, (iii) service providers for the IT infrastructure’s implementation, development, management, assistance and maintenance, with particular reference to the management software and portals/platforms used to manage relationships with Suppliers and the CRM used for marketing purposes; (iv) providers of management software, applications, hardware and the related assistance and maintenance services; (v) providers of connectivity and email services and the related assistance and maintenance services; (vi) legal, accounting, tax, environmental and health and safety consultants; (vii) banks/credit institutions and insurance companies; (viii) public authorities/entities, even for purposes different from the ones for which Data have been originally collected.

8. TRANSFER OF DATA TO THIRD COUNTRIES (EXTRA EU OR EEA)

In principle, Data are not transferred to third countries outside the European Union or the European Economic Area. If such a circumstance should occur, the transfer, in any case, shall take place upon verification of compliance with articles 44 and following of the GDPR.

In particular, the transfer of Data – if any - from IPI to other group companies, located outside the EU or the EEA will take place on the basis of intercompany agreements and after having signed the applicable standard contractual clauses.

Exclusively for products to be delivered to recipients located outside the EU or the EEA, the relevant transfers of Data, will take place according to art. 49 lett. b of the GDPR as it will be necessary for the performance of a contract entered into by the Customer and IPI.

9. RIGHTS OF THE DATA SUBJECT

The data subjects, using the contact details provided in paragraph 2, can exercise the following rights:

- right to obtain information on the processing and access to the Data (articles 12, 13, 14 and 15 GDPR);

- right to rectification (article 16 GDPR);

- right to erasure (article 17 GDPR);

- right to restriction and to object the processing (articles 18 e 21 GDPR);

- right to be notified in case of rectification or erasure of personal data or restriction of processing (article 19 GDPR);

- right to data portability (article 20 GDPR).

10. RIGHT TO OBJECT

According to the same modalities set out in the paragraph above, the data subjects can object, wholly or partially, to the processing of the Data where the relevant legal base is represented by the legitimate interest of IPI, in accordance with article 21 GDPR.

11. COMPLAINT

Every data subject who believes that the Data concerning him or her are processed in violation of the GDPR, shall have the right, according to article 77 GDPR, to lodge a complaint with a supervisory authority in the Member State of his or her habitual residence, place of work or place of the alleged infringement. For more information, here’s the link to the Italian Supervisory Authority: https://www.garanteprivacy.it/web/garante-privacy-en/home_en.

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