In the field of tomato processing for sauce manufacture, a European multinational that had previously collaborated with CFT Group on a project in Australia experienced significant challenges with the packaging technology.
This equipment, essential for serving the food service and canning industry, was frequently plagued by product losses and damages.
The tomato sauce process involves aseptically filling polyethylene pouches while hot, subsequently cooling them to approximately 40°C. Prior to boxing, these pouches are labelled or ink-marked. However, the line required a substantial upgrade to double its productivity, accommodating around a hundred different pouch formats.
These formats varied in weight from 1.5 to 7 kg and in viscosity from gel to liquid. A critical requirement was to maintain a firm grip without deforming the pouches, as secondary multi-bag packaging demands precise insertion to eliminate empty spaces within cartons, ensuring optimal box filling.
The challanges for the tomato sauce industry
To address these challenges, CFT Group introduced a new twin packaging line alongside the existing setup, complemented by a final palletizer serving both lines. The cornerstone of this upgrade was the implementation of two Kenos® KVGL grippers equipped with piGRIP® BGI48 suction cups from the Piab Group.
These grippers, available in two sizes, were fitted with tool changers:
- KVGL 220×200 mm for handling pouches weighing 1.5 to 3 kg;
- KVGL 330×220 mm for those between 4 to 7 kg.
Despite initial concerns over grip quality and suction cup durability, the decisive factor for the customer was the tests and demonstration videos provided by Kenos®.
“Unlike the traditional hood solution, Kenos® KVGL grippers with piGRIP® BGI48 suction cups allow for safe handling without deforming the pouches,” explained Luigi Diani, Mechanical Coordinator of CFT Group and project manager. “For vacuum generation, Piab’s COAX® ejectors were integrated into the KVGL grippers: Four cartridges in the small gripper and eight in the large gripper. This innovation allowed the client to forego using an external vacuum pump, resulting in significant energy savings.”
The blow-off system ensures the grippers remain clean, and thanks to the technologies from Kenos® and Piab Group, maintaining the gripping system has become remarkably straightforward.
Luigi Diani further commented, “The timely assistance from Kenos® technicians and the consultancy provided by Chiara Nannicini of CCRE, the official distributor of Piab Italia, added immense value to the project. The collaboration between Piab Group and CFT Group facilitated the development of a highly customized and efficient solution, capable of meeting all the needs of our customer.”
Kenos® vacuum gripping systems streamline handling in the food and packaging industries. Designed for versatility, they manage diverse objects of varying shapes, sizes, and materials. These systems offer integrated or external vacuum generation options. The KVGL model stands out in the packaging sector, providing adaptable solutions tailored to specific needs.
piGRIP® is an exclusive configurable suction cup concept, with individually optimized parts to facilitate gripping, lifting, and level compensation of various types of objects or surfaces, ensuring fast and safe movements.
COAX® vacuum technology reduces energy consumption with secure, fast gripping due to its high initial flow. It performs well even with low or fluctuating supply pressure. Tests by the Fraunhofer Institute showed that Piab ejectors use significantly less compressed air than competitors, lowering compressed air supply costs and total production costs.
