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    Repacking lines

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    Repacking is certainly not a new concept, but the technical innovations introduced by ACMI have opened new possibilities for repackaging, especially for soft drink makers.

    The line that we will introduce features high automation and greater flexibility both in the depalletising and repackaging phases, thus offering interesting solutions to the large international bottling groups.


    This innovative repacking line allows many repackaging options ranging from three types of product: can packs, bottle packs, bulky PET bottles on shaped trays, bulky PET bottles on cardboard trays and bulky cans on cardboard trays. Being equipped with three inbound loading stations, the line can mix up to three different flavours, palletising directly on pallets or on a tray.


    Before moving on to the line description from a technical point of view, it is advisable to list the possible repacking combinations that can be obtained:

    • repalletising same flavour packs on different sized pallets compared to the original size;
    • repalletising same bulky bottles on different sized trays compared to the original size;
    • repalletising packs and mixing of flavours on different sized pallets compared to the original size, generating mixed flavoured pallets;
    • repalletising bulky bottles and mixing of flavours on different sized trays compared to the original size, generating mixed flavoured pallet.

    Infeed pallet types

    The afore-described combinations can come from the palletised magazine on:

    • CHEP 1200x1000
    • EUROPALLET 1200x800
    • Dusseldorfer 800x600
    • shaped 800x600 plastic tray

    Outfeed pallet types

    The depalletised and mixed products from the repacking line can be repackaged by choosing from seven types larger-sized pallets or trays, 1200x1000 up to tray quarters (plastic or cardboard) or flat interlayers, including trays with wheels.

    The line

    Moving on to the description of the line from a technical point of view, it has an infeed system consisting of three independent loading stations. These stations consist of conveyor belts that transport the product pallets to the two depalletising robots equipped with special gripping heads. The gripping heads represent the focus of the entire depalletisation system which is able, on the one hand, to depallitise can packs and bottles by taking them “by row” and, on the other, by means of an automatic exchange system from the head itself, to pick-up the bottles from the shaped plastic trays. The pick-up head is equipped with a camera system to correct any tray imperfections and always ensure perfect centring during the product pickup phase. Once depalletised, the two types of product, packs (of bottles or cans) and bulky bottles, follow two different paths, to meet again at the palletisation area.

    Twisterbox and Traymax

    The bottle or can packs coming from the three depalletisation lines, once depalletised, they proceed to the Twisterbox layer formation system that, in addition to forming the layer, also mixes the flavours so as to deliver to the palletiser one layer of product with mixed flavours. However the Twisterbox can also handle only one flavour type when the purpose of the repacking line is to change the final pallet size moving for example, from a Europallet to one quarter tray. Not only, as the system is not only able to reduce the pallet size, but it can also insert the product layer into cardboard half and quarter trays, and then palletise them on pallets. In the case of tray package insertion, the Traymax tray former comes into play, another key element of this central part of the line which, logistically positioned alongside the Twisterbox, performs two functions: on the one hand it has the task of repacking bulky bottles (and also to mix their flavours, three at most) when the line is set up with this type of program and from the top it has the task of producing empty trays for palletising layers composed of packs (cans or PET bottles) produced by the Twisterbox.


    The palletisation phase is entrusted to three Condor robots with specific gripping heads: the first, located at Twisterbox and Traymax outfeed, is equipped with a pick-up head with perimetric pads and inserts the product layer inside the trays produced by the Traymax (in this case the line can generate trays of the same flavour or with mixed flavours); the second, equipped with an openable platform head, palletises shrinkwrapped pack layers prepared by the Twisterbox, and the trays with bulk bottles prepared by Traymax tray former; the third robot, equipped with a special gripping head, manages and supplies pallets and interlayers that feed the palletising process.

    Pallet stretch wrapping

    The line ends with a wrapping system consisting of three pallet stretch wrappers, capable of handling numerous combinations. The first two pallet stretch wrappers, positioned close to the palletisation area, are two Vortex 1000 fixed-pallet systems, whilst the third wrapper is a rotating table pallet stretch wrapper Rocket model. All three pallet stretch wrappers mount a one meter reel and are equipped with the ACMI patented electronic pre-stretching system (film pre-stretching value is above 400%) and the automatic change over system of the entire pre-stretching unit. The most complex configuration is that where the first Vortex pallet stretch wrapper wraps the pallet quarters, the second Vortex pallet stretch wrapper wraps the pallet quarters two by two thus generating a half pallet and the third and last pallet stretch wrapper wraps the two half pallets together once these have been placed on a “mother” pallet, generating a whole pallet. This is not a compulsory wrapping combination, but it is the one in which each machine wraps a different pallet size: quarter, half, full... if this is not flexibility!

    Twisterbox Fenix Condor Faster Thunder Rasar Spider Rotofilm Conveying systems and automation Pet lines Pet compact lines One way glass lines Returnables Glass lines Can lines Keg lines Jar lines HDPE lines Brik lines 5 gallon lines

    In caricamento...