Customer benefits

Purpose-built configuration

Industry leading box-forming technology

8,000 bottles per hour

Assembly integrity

Key parameter product quality inspection

Minimal waste

Significant reductions to production cost

Fast-track machine delivery

Collaborative approach

Company

Luxury champagne house, Veuve Clicquot Ponsardin (VCP).

Challenge

To develop and deliver a unique, special cartoning, automated system for the assembly of a high-quality, champagne bottle packing solution.

The unique, eco-friendly pack design comprised two parts: a complex inner drawer (barquette) supplied as a large flat blank, and an outer sleeve (fourreaux) in the form of a pre-glued skillet.

The inner and outer parts could be partially separated to present the champagne bottle to the customer; it had to be securely held with the label and supplier emblems facing forward with an appealing ‘open draw’ like presentation.

Traditionally assembled using high volumes of manual labour, automating such demanding tasks had previously been thought to be beyond the scope of conventional machinery capability. Yet, through the ingenuity of its engineers, Mpac was able to automate every element of this complex process and still deliver the highest level of quality as well as significant savings in labour costs.

Solution

The specific demands of this project required a bespoke approach, where special purpose machinery was integrated seamlessly with standard solutions.

Two Fanuc robots were used to start the fully automated process; loading stacks of the flat inner drawers directly from the pallet into the magazines. Importantly, these fully-automated machines also managed waste packaging recovery for improved recycling.

To then construct the highly complex, multi-folded drawer, we accessed our vast product handling experience to design a bespoke, multi-station, continuous motion rotary turret. This creation is now widely acknowledged as a significant milestone in modern box-forming technology.

Further customisation of the system was required to ensure the next steps were handled efficiently. First, our team of experts designed a transfer station capable of changing both the pitch and orientation of the inner drawer to facilitate its smooth transfer to a further turret system, custom-designed to bring together both the inner draw and bottle.

With bottles delivered randomly to the turret, on board systems were provided to detect the position of the label. Each bottle could then be rotated the required amount before placing in the draw; ensuring the label would be presented facing outwards from the opened package.

The final placement of the inner draw with the bottle inside the outer carton was handled using a proven, specialist, secondary packaging machine, which was adapted to meet VCP’s unique requirements and supplied as part of Mpac’s fully integrated, special-purpose solution.

Interested in understanding how we tackle complex challenges like these?

Call us on: +44(0)24 7642 1100