A breakthrough innovation: our Robotic Unscrambler

Box

Boxes are adopted mainly when you have to store various formats of containers that differ in shape, or, although they have the same shape, vary in colour or label. The easiest, most effective, flexible and safest way to store the quantities of containers required in a “just in time” manner is the Lanfranchi box system. The containers are available in various sizes and capacities up to a maximum of 10 m3 and can be stacked and transported by truck.

Gentle Bottle Silo

It is mainly used as dynamic storage in palletising and filling lines, or in extrusion lines.

It is also used when in an installation with a preform press connected directly to a blow moulding machine it is necessary to reduce the temperature of the preforms in order to make the heating and blow moulding process as homogeneous as possible.

The name itself identifies the result that is intended to be achieved with the creation of this new dynamic storage system, which enriches and completes the range of traditional systems.

The main characteristics of the Gentle Bottle Silo are:

Gentle bottle handling;
Possibility of storing very light bottles;
Absolute certainty of the “first in first out” system;
Reduced installation times.

Silo for aseptic application

Lanfranchi Ultraclean Silos are the ideal solution if you need a protective buffer for your blow moulding machine and you want to be sure that the bacterial load of the bottles does not increase while they are stored inside the silo.

Lanfranchi Ultraclean Silos was built entirely with AISI 304 stainless steel, it does not feature any point of retention, it is equipped with a CIP system and is guaranteed Class 100.

Conditioned panel silos

Conditioned type of panel silos developed specifically to fulfil the storage needs of the milk sector, where containers are made with HDPE and are completely closed.

The main problem with handling this type of container is controlling the inside temperature of the silo, to avoid phenomena of implosion or explosion of the container.

The problem was resolved by developing a silo system with a precise division of the air at different temperatures based on the position of the container inside the silo.

Temperature control is guaranteed through the use of insulating sandwich panels to create the silo roof, side walls and hopper.

Silos Fast

The Silos Fast storage system has been created to be used as buffer for water and soft drink lines, but it can also be used for major storage. This product incorporates three fundamental elements:

The consolidated operation of a Lanfranchi silo;
Modular structure;
The quick and simple assembly process which drastically reduces installation times.

Conveyor belts for bundles and cases

Lanfranchi conveyor belts for bundles and cases are built based on what product needs to be handled. The robust main structure of the conveyor belt is stainless steel.

Conceived with the model of modularity, they are easy to install and easy to connect to the machines that comprise the production line.
Single line or multi line, they have side guides that can be adjusted manually or automatically.
On the same line, based on what product is being handled, different types of conveyor belts can be used, which are installed ensuring that the transfer from one to the other is fluid, that no jams or damage occur to the product.

Dynamic Accumulation Table

According to the characteristics of the product being handled, Lanfranchi offers a broad range of accumulation tables. The design takes into account system needs and Customer specifications. The following types of accumulation tables are available:

No pressure multi-row “FIFO” accumulation table, The containers flow freely during normal production. When a slowdown happens, the containers start accumulating on the multi-lane conveyor without pressing against each other. This application is particularly suited for delicate and costly products.
Standard “FIFO” accumulation table, the containers flow freely during normal production. When a slow-down happens, the containers start accumulating on the accumulation table, lining up with the aid of specific guides.
Two-way accumulation table, this solution is helpful when the product temporarily stops flowing and temporary container storage is necessary. When the blockage happens, the programmed guide deviates the containers from the main conveyor on the two-way accumulation table. The reverse happens when the downstream blockage is resolved and the containers are sent from the accumulation table to the main conveyor belt. The accumulation logic in the case is LIFO and accumulation occurs randomly.
The Rotary table accumulation system is composed of a steel disc, which rotates by a gearmotor complete with variator, to synchronise rotation speed with feed belt speed.

Table-Top Conveyors

Lanfranchi table-top conveyor belts are designed for high speed handling of all types of containers with maximum accuracy. The flexibility required for creating the layout of more complex lines is made possible by the concept of modularity, that Lanfranchi table -top conveyor belts are conceived and built with. This modularity allows for quick installation. With the Lanfranchi modular concept, integration into existing lines comes naturally.

Modern yet functional design.
Main structure of conveyor belt made of stainless steel.
The type of chain and/or belt is optimised based on container type
The side containment guides, designed to prevent damage to containers and labels, are built with AISI 304 stainless steel and high density polyethylene contact profile.
Guide position can be adjusted manually or automatically.
The standard height of the work surface can be adjusted by ±50 mm by the feet.
The electric conduit is available in various types and integrates perfectly into the main structure.
The silicone or water-based dry lubrication system is available as an optional.
Upper covering of conveyor belt available in several versions.

Elevator and Lowerator

Thanks to the elevator or lowerator, the containers are conveyed with considerable changes in height, reducing the footprint to a minimum. According to the physical and morphological nature of the containers, Lanfranchi offers a broad range of elevators and lowerators:

Pad gripper elevators/lowerators
Aspirated/pneumatic elevators/lowerators
Magnetic elevators/lowerators
Helical elevators/lowerators
Steep ramp elevators/lowerators

For every type of application, thanks to their specialised multi-year experience the Lanfranchi team and offer the best solution.

Bulk conveyor belts

Our bulk conveyors have been developed in order to reach the excellence in the handling of the containers and are destined to handling of the containers before the unscrambler.

The numerous customisations provide, for example, the possibility of using plastic nets or rubberised belts. The hoppers can be increased and motorised to create micro accumulations of different sizes directly on the line. A dirt protection cover can be installed on request.

Automation has also been optimised for this type of conveyor.
For many people, a bulk conveyor belt is just a coarse conveyor.

For Lanfranchi is a fundamental element of the lines of its Customers.
The structure of the conveyor belts and the possibility of combining covers, make Lanfranchi belts particularly “clean”. Even the hoppers, which are designed to optimise container handling, can be covered. The edges of the conveyor can be opened for easy access inside the conveyor belt and thereby simplify cleaning and special maintenance activities.

Table-top conveyor belts

The Lanfranchi range of products for the handling of empty plastic containers also includes conveyor belts with suction and without suction. The main advantages of Lanfranchi conveyor belts are:

Main structure of conveyor belt made of stainless steel.
Stainless steel vacuum chamber separated from the conveyor belt frame to guarantee a better vacuum level along the whole length of the conveyor.
Connections between vacuum chamber and conveyor fitted with butterfly valves so that the vacuum level in the bottle collection tracts can be adjusted.
Ventilator for vacuum generation fitted inside an insulated and soundproofed steel casing.
Upper covering of conveyor belt available in several versions.

The belt vacuum units are completed with a wide range of accessories with which it is possible, for example, to obtain divisions from one to several rows or to increase the cleanliness features of the conveyor. Also for this type of conveyor, automation has been greatly refined so that, for example, the vacuum levels can be set and checked according to the different sizes to be processed. Both the conveyor belt frame and the vacuum chamber underneath are made of stainless steel.

Various types of conveyor belt covering are available: from the upper dust cover to a complete casing.

The suction fan is housed inside soundproofed casing. By using the butterfly valves inserted in the connections between vacuum chamber and conveyor belt, zones with different vacuum levels can be defined, such as in the collection tracts, for example. All the components of the table-top conveyor belts (alongside conveyor sections, the bends and the separators) are also available for the vacuum conveyor belts.

The chains of the vacuum conveyor belt are perforated according to the type of container being handled.

Air conveyor belts

Lanfranchi is able to transport PET or HDPE bottles at high speeds ensuring high efficiencies. All the components (curves, assemblies, dividers, etc.) have been designed with the aim of maximising the efficiency of the line.
The Lanfranchi air conveyor belt is available in three versions:

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2

3

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2

3

Basic

Recommended for soft drinks, edible oil and detergents. i.e. for transporting products that require a basic degree of air filtration.

Clean

Recommended for water, juices and any other application for which the air that comes into contact with the bottle neck is treated with higher grade of filtration than the Basic version.

Ultra Clean

The possibility of an increased bacterial load inside the containers is eliminated. A special system for air recirculation allows to recover and filter the air over and over helping to extend drastically the life of the filters.

The levels of filtration that can be supplied are three:

Pneumatic conveying systems

Lanfranchi pneumatic conveyor systems are robust and provide efficient results in handling empty plastic containers of different types: from PP to HDPE. Pneumatic conveyor systems are made of steel but the PVC tube version is also available which requires low maintenance.

LARGE PIPE

This product carries containers or rejects for long distances effectively and efficiently. The containers move through the pipe without hitting each other, thereby guaranteeing container integrity. The large diameter pipe can be installed externally, offering simple and effective logistic solutions. The minimum power installed refers to the distances that can be covered with a single fan.

SQUARE MODULAR TUBE

This rectangular transport system is designed for plastic containers of any sector. Thanks to the finger-joint system, with modules that can be easily disassembled, there is the possibility of obtaining different things, for example:

• Possible chutes and hoppers for start and end of line
• Visual inspection mirrors
• Any kind of special accessories, such as hatches on bends for inspection or maintenance without disassembly.

PNEUMATIC BOTTLE CONVEYOR

This version of pneumatic conveyor uses pipes with smaller diameters compared to the previous version. The system allows the insertion of flow dividers up to six lanes, offering the customer greater flexibility of use.

unscrambler vacuum sliding surface upgrade

Vacuum sliding plane Upgrade

Lanfranchi has introduced a new update available for all its unscrambler models to respond to the continuous lightening of PET bottles. Lightweight PET bottles bounce around more and are harder to control.
But now, thanks to the Vacuum Sliding Plate system, the Lanfranchi Unscrambler is ready to compensate for this instability by drastically reducing bottle jumps and keeping the speed of the unscrambler high.

The vacuum sliding plate quickly stabilizes a bottle inside the cradle and keeps the bottle in the ideal position for the following step of controlled drop through the funnel ending with the bottle standing up and ready to exit the unscrambler.

So, among the positive aspects of this upgrade is the increase in efficiency in the reordering process with more bottles correctly positioned within the funnels during rotation.

Silo Light Upgrade

Our customers require a solution for stocking lightweight bottles, such as PET, PE, PP or HDPE, so Lanfranchi has designed a new system to reduce the load inside the silo. This new system can also be installed on existing silos such as FAST silo, Ultra-Clean, etc. and purchased as an upgrade.

The main concept of this application is to distribute and reduce the pressure of the bottles placed in the upper part of the silo compared to those in the lower part. It consists of a continuous series of inclined panels that are inserted inside the silo, dividing it into areas, the first effect of which is a uniform distribution of loads over the entire length of the silos (horizontal loads during the emptying operation).
Another important result is that these continuous baffles also reduce vertical loads. Thanks to their inclination, the load of bottles placed at the top does not have an impact on the load of bottles placed at the bottom.

Vacuum Star-wheel Upgrade

With the Aspirated Star-wheel your bottles will not suffer a single scratch and you will no longer have to replace stars at every format change and have excessive encumbrance. If the range of bottles to be processed is very wide, the Vacuum Star-wheel is equipped with interchangeable and removable inserts. In most cases, two sets are more than sufficient to cover the entire range of bottles. The inserts are easily and manually applied. The vacuum itself and a mechanical interface, calculated at the design stage, keep these inserts in their positions.

How the Vacuum Star-wheel is being installed:

The upgrade consists of a pre-assembled unit that will allow easy installation on site. The old machine substructure will be dismantled on site (except for the lexan guards, which will be reused) and then the new pre-assembled unit will be installed, which will consist of the new substructure, the vacuum chamber, the vacuum star-wheel and then the fan complete with motor.

Click Clack Lifter Upgrade

Thanks to Click Clack the Lanfranchi Unscrambler becomes even more flexible, practical and user-friendly. You can change the format of your bottles with a simple click!

MAIN ADVANTAGES:

No tools needed

It is not necessary to dismount parts: thanks to a hidden spring, you just need to raise or lower the lifter’s block with a click.

Reduced time for change over operations

Thanks to the removal of the polyethylene blocks to be dismounted and reassembled, with a simple click-clack on the lifters it is possible to significantly reduce the operational process needed for each changeover.

No stock needed

By using Click Clack Lifters, it is possible to eliminate stock of pieces needed for the changeover.

Reduced errors during change over operations

The parts needed for the changeover leave the facility already installed on the machine and tested, reducing the possibility of errors due to the mixing of the parts.

BFS Upgrade

System for reduction of compressed air consumption in unscramblers.

The new BFS system has the function of removing bottles in excess and misplaced inside the puckets.
The system is composed of fans ( from 2 to 8, depending on the model of the machine), which have an installed power of 0.85 Kw.

The main advantages of the BFS are:

Compressed air consumption reduction
Noise reduction (from -3 to 5 db)
So big energy saving

The system can be used, on request, with the integration of filters, to create a slight overpressure of clean air, inside the machine.

The system is available to upgrade existing lines, even those not supplied by Lanfranchi.

Infinity Upgrade

This Upgrade can be installed on both table-top and air conveyor systems.
The micromotor used to move the side guides consists of a compact unit that includes:

Motor
Gearbox
Encoder

The motor powers a threaded rod that is connected to the side guide.
The length of the rod can be varied according to need, so this system is truly ‘infinity’.
These motors were tested at Lanfranchi for months, having them changed thousands of times a day to check their reliability, and the component worked flawlessly.
The micromotor that controls the vertical movement is attached to the C-channel and to the bracket on which the other micromotor is mounted.
Since the lower micromotor must move up and down, the bracket is connected to a linear guide fixed to the side of the C-channel.

The system is available to upgrade existing lines, even those not supplied by Lanfranchi.

LACO Changeover Upgrade

With LACO, the changeover is quick.
The LACO concept is based on the very simple ‘release, slide and lock-in’ formula in which the operator moves the lower part of the funnel into mechanical positions that are clearly marked; the cradle requires only a tool-free replacement of a separator according to bottle size. In the faster models of unscramblers with separators, the standard use of the vacuum star-wheel and the LACO design may eliminate the need to replace separators.
The format change operation is easily taken care of by a single unskilled operator and according to the machine model and bottle characteristics can range from 5 minutes up to a maximum of 30 minutes.

Laco funnels, with predetermined manual adjustment, process all sizes of bottles and do not require changing parts. Adjustment of the new Laco funnel is done simply by moving the knob to the position indicated for the bottle format to be processed, thus avoiding operator errors.

Lanfranchi Group