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Efficient format adjustment in the beverage industry

Automation made easy!

Rivella AG is the largest group of companies for soft drinks of Swiss origin and, with a brand awareness of 93 per cent, is one of the strongest brands in Switzerland.

The drinks are bottled in Rothrist in the canton of Aargau – with the support of drygear Apiro gearboxes from igus, which enable flexible adaptation of the conveyor belt.

Rivella bottling line with Low-Cost Robotics and sensors for bottle transport.

Profile

  • What was needed: A format adjustment system that can handle different pack sizes and is also suitable for use in the food sector. In addition, the aim of the automation solution from igus was to reduce set-up times.
  • Requirements: Lubricate-free & maintenance-free in order to prevent production downtimes, as well as being inexpensive to purchase. Due to the growing variety of products, flexible adaptation is desired.
  • Sector: Processing/packaging industry
Bottling line with bottles on a conveyor and Low-Cost Robotics components in production.

Problem

Save costs through automation in maintenance – minimise set-up times

Wherever beverages are produced, the demands on machines and systems are high. Hygiene regulations must be adhered to, precise format adjustments and fast movements have to run smoothly. The demands on the flexibility of modern production systems are constantly increasing. This is due in particular to the growing variety of products. In addition to high plant availability, manufacturers are also dependent on shorter set-up times at the different stations of their machines. The machinery at the Rivella production site in Rothrist is also constantly being modernised and updated and, where possible, automated.

Products used

Apiro wormgear standard gearbox with visible flange and connecting shaft.
drygear Apiro gearbox with hollow shaft
igus dryve D1 control unit with connectors and status display.
D1 dryve motor control
Rotary encoder with shaft and two connectors, cut out.
drylin E stepper motor NEMA23

Solution

drylin & drygear: Lubrication-free linear guide & Apiro gearbox system

This solution consists of two lubrication-free drylin SLW lead screw units, each of which is connected to an Apiro gearbox. With the Apiro gearbox, a strong connection can be established between the two drylin lead screw units, thus ensuring synchronised parallel adjustment of both axes. The solution is completed by the motorised drive in conjunction with a D1 dryve motor controller – the in-house motor control system from igus.

Thanks to the ease of use of the control system, the system could be set up within a very short time. Rivella has programmed three positions, one for the 0.2-litre, one for the 0.5-litre and one for the 1-litre packs. All the operator has to do now is select the program, press a button and the system automatically adjusts the print heads to the desired height and position. Rivella now needs less than a minute to change the product date compared to up to an hour previously, and does so reliably, maintenance-free and lubrication-free.

Does it have to be so ... elaborate? 🤔

Not any more! In co-operation with igus, Rivella AG has automated lane adjustment – and achieved up to 98% less downtime in the process!

Find out more about format adjustment now

Format adjustment using clamps

Linear guides with manual clamp

To the advantages and products
Manually driven linear axis with drive unit and sectional view of the guide.

Manual format adjustment

Linear axes driven by hand wheel

To the advantages and products
Control unit and motor for an igus system on an orange background.

Automated format adjustment

Linear axes with motor and control system

To the advantages and products

Consulting

I look forward to answering your questions

tejas
Tejash Shrikrishna Chavan

Industry Manager - Packaging

+91 9375440499 Write e-mail

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