FLEXPEED ASEPTIC SYSTEM
WELCOME TO THE NEW ERA
IPI has a longstanding heritage, providing a complete system in aseptic roll-fed technology and this to all beverage sectors; it is with great pleasure that I am introducing the new era of IPI with stronger commitments towards customers, employees and partners. For more than 35 years, we have been active in supporting the development of the aseptic liquid food segment and opened up markets worldwide, consequently achieving a solid recognition and reputation of being a reliable full system supplier for sterile packaging. Since 2013, IPI has been part of the COESIA Group, known for its outstanding and leading engineering expertise throughout industries like aerospace, formula one cars, pharmaceuticals, cosmetics and other highly specialised sectors, requiring unique skills. With our passion and know-how, we are embarking a new path, which we are proudly unveiling by introducing the most advanced machine technology and the creation of distinctive innovative packaging solutions. We intend to Shape the Life of your needs, providing you with valuable alternatives when selecting your future partner in aseptic system; because having an option to choose really matters. With our newest Flexpeed Aseptic - FX120, we are most likely the first aseptic roll fed system supplier, introducing a revolutionary technology ready for Digitalization, PackML and IoT ensuring reliability and flexibility at its highest industrial performance. We stand behind our commitments and values, as we intend to better the everyday life of stakeholders involved in the aseptic beverage sector. We firmly believe that Flexpeed FX120 has significant benefits, offering a changing future in shapes, technology and flexibility. Imagine having the flexibility in shapes making your brand and product iconic - The Shape of Life.
WHEN SMART ENGINEERING MEETS ASEPTIC KNOWLEDGE FLEXPEED is the breakthrough innovation in the aseptic carton packaging for liquid products, outcome of the combination of IPI know-how in aseptic technology and Coesia expertise in machine automation. 100 years of leading experience, unique aseptic platform worldwide. When developing FLEXPEED system, we were always driven by both consumers trends and customers looking for solutions able to open the new era of the aseptic carton packaging. A state-of-the-art technology, made in Italy.
THE FLEXPEED SYSTEM, COMPETITIVENESS TODAY AND TOMORROW We dreamed about a new reliable aseptic filling platform able to guarantee flexibility needed to adapt business to evolving consumer demands, brand strategies as well as production requirements without limiting high speed performance. We did it. Enabling easily change package sizes and shapes, FLEXPEED helps achieve business growth objectives, while increasing return on investment and capacity utilisation.
SHAPES TO STAND OUT We have designed FLEXPEED as an open-minded
machine,
ready
now
to form and fill from regular brick to distinctive and innovative packaging shapes.
RESPONDING TO “MARKET DESIRES” FLEXIBILITY “ONE MACHINE, UNLIMITED RANGE OF SIZES & SHAPES” The FLEXPEED system gives a never seen range of existing and future packaging formats and volumes thanks to 1D Fast and 3D changes. 1D Fast change option enables to switch from one pack volume to other formats with the same cross section in only 15 minutes. FLEXPEED platform makes it possible, by means of 3D change kit, to switch from family to portion pack and vice versa - also among different shapes - during about 2 working shifts.
RELIABILITY “ROBUST, SIMPLE AND SAFE ASEPTIC MACHINE” Full mechanical transmission has been adopted in order to ensure simple and robust machine in production. In addition, the use of a well-established aseptic technology and top quality packaging material is key to make final product safe, stable and nice to look at.
EFFICIENCY “OPERATING COST REDUCTION” Long term profitability depends also on filling machine and overall system line efficiency. In view of this, when developing FLEXPEED platform particular attention was given to cost reduction per manufactured package. The filler is easily accessible and can be operated with minimum manpower. Moreover, low utilities consumption as well as minimal machine downtimes and wastes are ensured.
SPEED “HIGH PRODUCTIVITY WITH FLEXIBILITY” FX120 is the fastest flexible roll-fed aseptic filler worldwide. Up to 12,000 pph for portion sizes (100 - 375 ml) Up to 10,000 pph for family sizes (500 - 1000 ml) FX120 has an adjustable speed to existing downstream and processing equipments.
VERSATILITY “READY FOR FAST MOVING TRENDS” FLEXPEED looks ahead. Designed to form and fill special shapes and sizes whenever product portfolio needs to be adapted to the market, thus effectively supporting quick renewal of brand and product policies.
SMART “HIGH CONNECTIVITY FOR EFFECTIVE OPERATIONS” FLEXPEED makes operations easier being equipped with latest generation tools for software and machinery functionality and connectivity.
FULL MECHANICAL TRANSMISSION The mechanical transmission guarantees high accuracy of movements resulting in high precision and repeatability in filling, strong sealing, high quality of the pack at high speed production. All movements are driven by a comprehensive system of gears and cams and don’t use hydraulic actuators nor hooking devices. All the critical parts are protected from contaminants.
FLEX FEATURES One touch on HMI panel to easily activate mechanical shift providing 1D Fast change. The sterile condition of the filler is preserved. The Fast change kit consists of few parts that need to be changed by the filling machine operator in short time.
RELIABLE ASEPTIC TECHNOLOGY Robust and reliable aseptic technology has been applied, resulting in a system of consolidated solutions with the highest performance. Sterilisation of the packaging material is reached when paper passes through a deep bath of hydrogen peroxide. FX120 integrates a compact aseptic chamber with sterile air flow. Sterilisation, filling and sealing processes are continuously controlled, ensuring highest safety quality standards. Integrated CIP and COP units.
QUALITY OF FINISHED PRODUCT Adaptive induction system guarantees high quality on sealing and reliability of each single package. Packs movements are always accompanied in all phases and never left to the inertia of the package itself. In this way, the machine optimises package handling, avoiding product damage, wastes and machine stoppages. Advanced web tension system provides high precision on pack forming.
ERGONOMIC DESIGN Innovations in product flow and machine layout allow for easiest access to all main groups. In case of multiple filling machines layout, one operator can control both machines at the same time.
MODULAR DESIGN FLEXPEED has been conceived to be integrated hosting downstream equipment (such as straw or cap applicator) in order to be even easier to operate and reduced in footprint.
HMI Human-Machine Interface (HMI) panel is an intuitive touch screen through which operators can directly control and monitor production process. It provides: • Main data and production performance indicators • Advanced trouble shooting to easily perform machine diagnostic • Energy consumption monitoring of each functional group • Remote monitoring and trouble shooting through Wi-Fi connection
AUTOMATION The system is equipped with automatic change for packaging material reel and sealing tape. The smart solutions adopted in the material loading area prevents stoppages, increasing filler efficiency
PARTNERS FOR SUCCESS With our team of experts, we closely collaborate with customers offering a full range of tailor-made solutions. • Engineering and layout • Production site preparation • Equipment installation and commissioning • Quality assurance • Production start-up • Training activities • Preventive Maintenance & Service product
BOOSTING PERFORMANCES, SMARTLY
FLEXPEED was developed in response to customer need for digital production data that is crucial for delivering maximum performance. FLEXPEED is designed to be compatible with any smart equipment (PackML compliant), making it possible to monitor complete line performances by using the integrated HMI while - in order to properly monitor two or more filling lines at the same time - Data Collection System (DCS) is offered. DCS automatically collects operational data presenting them in real time through a user-friendly web interface that can be accessed from any computer or mobile in your local and remote network. Main benefits: • Overall Equipment Effectiveness (OEE) increase with optimised machine utilisation • Ready-to-use data • Operational cost reduction • Machine operator performance assessment • Waste reduction • Targeted and preventive maintenance • Energy consumption monitoring
DCS DATA COLLECTION SYSTEM (for multiple packaging line)
PREDICTED MAINTENANCE & IMPROVEMENTS SERVICE
FX120 FILLER (integrated monitoring)
PACKML COMPLIANT
REMOTE SUPPORT
USERS DOWNSTREAM
ERP
ERP
CUSTOMER PRODUCTION PLANT
IPI
FLEXPEED PACKAGING LINE
A great filling machine needs to be well-supported by a reliable downstream equipment in order to guarantee maximum production efficiency over time. IPI is a full system supplier providing complete range of processing and packaging systems. Whatever the format, size, opening and secondary packaging you need, the right equipment solutions will be easily configured to work at best.
EXAMPLE A
FX filler
Accumulator
Cap applicator
Cardboard packer
Pallettiser
EXAMPLE B
FX filler
Accumulator
Straw applicator
Film wrapper
Cardboard packer
PACKAGE SPECIFICATIONS
Front, back and top packaging side view. Aseptic carton packages are ideal for liquid foods and beverages such as white, flavoured and enriched milk, juice, wine as well as tomato sauces, dairy alternatives, coconut water, feta cheese and other.
Multilayer material in reel is FSC and PEFC certified and produced in plants holding FDA, ISO 9001 and FSSC 22000 certifications.
5300 mm
MACHINE TECHNICAL SPECIFICATIONS
6450 mm
3600 mm
Max capacity
12,000 pack/h (100-375 ml) 10,000 pack/h (500-1000 ml)
Weight
13,200 kg
Electrical power connections
400 V, 3 Ph, 50/60 Hz, N+PE
Installed power
30 kW (average) 50 kW (capacity)
Cooling water consumption
3.5 L/min
Cooling water temperature
14 - 20 °C
Cooling water pressure
3 - 4.5 bar
Steam pressure
3.5 - 4 bar
Steam consumption
9 – 11 kg/h (sterilisation cycle) 2.5 kg/h (after sterilisation cycle)
Compressed air pressure
6 – 7 bar
Compressed air consumption
1,000 Nl/min
The information in this document is intended to provide the main product details. IPI reserves the right to make changes to the characteristics of the product at any time.
Milton Keynes, UK
Zurich, CH
Princes Risborough, UK
Göteborg, SW
Kalmar, SW
Holnon, FR Maple Grove, MN
Courcouronnes, FR
Covington, KY
Barcelona, SP
Milan, IT
Parma, IT
Florence, IT
99
OPERATING UNITS
32
Perugia, IT
Bologna, IT
COUNTRIES
59 of which are production plants
Bologna, IT
Bologna, IT
~7,000 EMPLOYEES
18
COMPANIES
Bologna, IT
Bologna, IT
COESIA Company Headquarter
COESIA in the World
COESIA is a group of innovation-based industrial and packaging solutions companies operating globally, headquartered in Bologna, Italy. Coesia’s companies are leaders in the sectors of: • Advanced automated machinery and packaging materials • Industrial process solutions • Precision gears
coesia.com
Coesia’s customers are leading players in a broad range of industries, including Consumer Goods, Tobacco, Healthcare, Pharmaceutical, Aerospace, Racing & Automotive and Electronics.
www.ipi-srl.com
IPI Srl Via Piermarini, 19 06132 San Sisto, Perugia – Italy T (+39) 075 528521 F (+39) 075 5285249 info@ipi-srl.com