T E C H N I C A L N E W S L E T T E R -

TECHNOLOGIES
Y E A R X - N U M B E R 1 - S E P T E M B E R 2 0 0 5

JAMNICA:
Aseptic full speed ahead
New aseptic line for
COCA-COLA NORBEGA
BARILLA:
Evaluating the suppliers
PLUS:
Line control software
“Procomac style”
WINE AND SPIRITS:
New developments
· 09/05 - 6000 · ENG

Aseptic Lines instal

led
Mod. 755/1
 Sales
Network

Procomac Technologies
TECHNICAL NEWSLETTER - Year X - Number I - SEPTEMBER 2005

Editing:
Media Management Dept.
Procomac Industries

Contatcs:
CARLO FERRARI
Group Media Management
c.ferrari@procomac.it
Tel. +39 0521 839411

Procomac S.p.A.
Via Fedolfi, 29
43038 Sala Baganza (Parma)
ITALY

Phone +39 0521 839411

Fax +39 0521 833879
E-mail: sales@procomac.it

www.procomac.it
Contents
Aseptic highlights 4
Zbyszko - Poland 4
Norbega - Spain 5
Galychina - Ukraine 6
Jamnica: aseptic
full speed ahead 8
Plus: line control software
“Procomac style” 12
Troy Aqua - Germany
YST - China
13
14
8
Cobecsa - Spain 15
Short news - Water 16
Procomac Engenharia:
Italian Quality made in Brasil 18
Pepsi Geusa - Mexico 20
Christis Dairies - Cyprus 21
Wine and spirits:
new developments 22
Barilla: evaluating the suppliers 24
Sella e Mosca:
tradition and innovation 26 12

26 24

POLAND
Night view of Swietokrzyski Bridge (Warsaw).
Zbyszko
GROWING TREND
THANKS TO PRODUCT QUALITY
Zbyszko was established in 1993
by Zbigniew Bojanowicz as a bott-
ling company for fruit-based CSD
and still drinks. Its modern produc-
tion facility is based in Bialobrzegi,
60 Km. south of Varsavia.
Zbyszko has always invested in the
latest technology to obtain an effi-
cient production system, based on
the guidelines of HACCP quality
control and ISO 9001 quality stan-
dards.
Innovation, investments, quality, a
wide range of products: these are
the main drives for a growing com-
pany trend in the last years.
Zbyszko is now the fouurth Polish
soft drinks bottles, with a distribu-
tion all over Poland and more than
2 million liters product bottled per
day.
A further drive for company growth
is the decision to enter the market
for aseptically bottled still drinks;
Procomac has been chosen as
technical partner for this project
4
Aseptic highlights
and has supplied a complete asep-
tic filling line designed for the
utmost versatility.
The sterilising/rinsing/filling bloc is
based on UNIBLOC 2 design with
neck bottle handling by gripping
starwheels; Bottle steriliser and
bottle rinser GRIPSTAR CX feature
electronic control of treatment
times. Fillstar CX 100 filler is
Procomac’s most versatile filler to
date in terms of containers and pro-
ducts: thanks to its new counter-
pressure volumetric electronic fil-
ling head it is possible to fill still
drinks without contact between
bottle and filling valve and carbona-
ted drinks with contact between
bottle and filling head.
The new aseptic line is completed
by bottle and packs conveyors,
integrated pro-
cess units for
fluids manage-
ment, Procomac
microbiological
isolator and Procomac CHECK-
STAR, a new full bottle inspector
designed and built by Procomac.
CHECKSTAR preforms fill level,
label and cap control and can be
used for authomatic bottle sam-
pling of the aseptic filling line, a
very important procedure that
ensures safety and quality of the
finished product.
With the deployment of the new
aseptic filling line Zbyszko is now
in a position to further widen its
production range by introducing
new premium products without pre-
servatives; this will be the key to
get a better placement among
Polish bottlers in the near future.
 SPAIN

New aseptic technology

for
Above from left:
Carlos Serrano (Aseptic
Project Manager,

Coca-Cola Norbega, Coca-Cola bottler

for northern Spain, has trusted Procomac
aseptic technology for a new aseptic filling
line. A contract has been signed in March
2005 between Norbega S.A. e Procomac
Spa to supply a Procomac SAFEASEPTIC
filling line for a production speed of 27.200
0.5 l. bottles per hour and 22.200 1.0 l.
bottles per hour.
Initially the products bottled will be from the
sport drinks range under Aquarius brand
and from iced tea range branded Nestea.
The heart of the line is composed by a
UNIBLOC 2 system with microbiological
isolator, GRIPSTAR 120 sterilizer with
electronic control of treatment times,
GRIPSTAR 90 rinser with electronic con-
trol of rinsing times, FILLSTAR Fx 70 elec-
tronic volumetric filler
Production of PET containers is handled
by a rotary Blow moulder SIPA SFR 16;
bottles are then carried to the bloc by
Procomac CONVAIR 2000 air conveyor in
aseptic version.
Norbega Norbega S.A.),
Vicente Gomez
(Technical Director
Norbega S.A.),
Luigi Baiocchi
(Export Sales Director,
A series of integrated process systems are Procomac Spa),
connected with the rest of the line to produ- Josè Luis Lanzagorta
ce sterilizing solution and sterile rinsing M. de Morentin
water (Unidox e Unitherm H), perform (Managing Director,
C.I.P. and S.I.P. cycle (Uniclean), produce Norbega S.A.),
washing foam for external surfaces was- Carlos Arostegui
hing (Unifoam), pasteurize the product (Legal Advisor, Norbega
S.A.)
(Unitherm T), sterilize the utilities (Uniflux).
e Joan Aubert
The installation is completed by the caps
(Sales Director,
sterilization system STERILCAP W3, PE Procomac Iberica S.A.).
labeller, SMI shrink-wrappers, low-level
infeed palletiser OPERA by Procomac
Packaging and Robopack pallet wrapa-
round.
The whole line is managed by Procomac
PLUS control software: All machines on
the line can be operated remotely from the
centralised control panel, all production
data are saved and processed, traceability
is guaranteed from raw materials accep-
tance to shipped batches of finished pro-
ducts.

5

GALYCHINA
Aseptic technology goes EAST
Consumer tastes are more and
more geared towards still drinks that
emphasize a "natural" recipe.
Therefore, aseptic filling technology to
fill still drinks without using preservati-
ves is gaining market acceptance,
especially by those companies that
recognize in the "natural drinks" a gro-
wing beverage segment for the of the
next years.
Within this market evolution a similar
attention to aseptic has been withnes-
sed in many countries of Eastern
Europe, such as Poland, Czech
Republic, Ukraine.
And tht's in Ukraine that Procomac
has signed a Contract for the supply
of a complete aseptic line for the
Company Galychina.
The aseptic filling line, based on the
concept UNIBLOC 2 with bottle neck
transfer, features a Gripstar Gx sterili-
ser, a Gripstar Gx 90 rinser under a
microbiological isolator. Filling is per-
formed by Procomac counterpressure
volumetric electronic filler Fillstar Cx.
Process equipment integrated to the
line to provide sterilizing solution, ste-
rile water, line CIP and SIP is in a new
version which represents the latest
evolution of Procomac Process
Systems. The key concept of these
6
UKRAINE
Left: a view of Kiev,
capital city of Ukraine.
Next page: the Golden
Gate Bridge over San
Francisco Bay.
new systems is the functional integra-
tion of the different components, that
has allowed a drastic simplification of
the system. The supervision software
of the line also manages all the pro-
cess units to optimize their operation.
The utmost care has been given to
reduce the consumption of sterilizing
solution: the plant is features a fully
automatic titration system for the ste-
rilizing solution and a water recovery
system for rinsing water.
Thanks to this new installation new
high quality
juices and
nectars will Versatile aseptic filling for
be introdu-
ced on the carbonated and still drinks
growing Fillstar CX is the latest innovation of
Ukrainian Procomac systems based on the prin-
ciple of the magnetic flow meter.
market; they
Pneumatically controlled valves are
will be produ-
used to obtain a versatile aseptic fil-
ced locally ling system able to treat both carbo-
and therefore nated and non-carbonated products
designed to with the highest level of safety and
fully meet the product quality. The filling valve can
local taste treat limpid products and products
and provide with pulps and fibres. Fillstar Cx is
an enjoyable available in a range of models from 50
to 140 filling valves for a production
experience to
speed from 18.000 to 67.500 1.0 l.
local consu-
bottles per hour when bottling still
mers. products and from 18.000 to 55.000
1.0 l. bottles per hour when bottling
carbonated soft drinks.
 Aseptic Solution
USA USA, LLC, is a R&D
company working in
the field of asepti-
cally filled beverages.
Its activity consists in
the development of
an aseptically filled
drink from recipe to
laboratory filling tests
up to the production
of small batches for
market tests purpo-
ses and large-scale
commercial produc-
tion.

ASEPTIC SOLUTION USA LLC

Aseptically filled drinks,
from conception to production

15 years of experience in the sec- GRIPSTAR GX 135

tor mean the availability of state of
the art equipments to handle the
whole process of ideation of a new
aseptic drink.
Procomac technology has been
selected to provide wide scale pro-
duction capability. To reach this
goal, a complete aseptic line type
UNIBLOC 2 Her with bottle neck
handling has been installed.
The line offers a productivity of
27.000 bpm on different formats,
from 6 to 32 fl. oz. for bottles in
PET and HDPE.
The sterilizing/rinsing/filling bloc
has got low acid products filling
capability (for example milk based
drinks). Containers sterilization is
performed by a rotary sterilizer
with electronic control
of treatment times; bottle rin-
sing is performed by rotary rinser
GRIPSTAR GX 90. The volumetric
electronic filler is a FILLSTAR Fx
70 with induction tunnel for the
welding of an aluminum foil on the
neck as a guarantee of the inte-
grity of the filled product.
An important feature of the line of
the line is the integrated syrup
room with UNISOLV BMP ingre-
dients dosing system, designed to
handle a wide range of solid, liquid
and powdered ingredients.
The line is completed by empty and
full bottles conveyors, pack conve-
yors and microbiological isolator
for the bloc.
Procomac has achieved
the 3A international certi-
fication for its milk filling
lines.
This certification formula-
tes standards and practi-
ces for the sanitary
design, fabrication, instal-
lation and cleanability of
dairy equipment, where a
high degree of sterilisa-
tion is required.
This certification guaran-
tees that the production
of Fillstar Fx systems
respects the standards
given by the 3-A Sanitary
Standard, Inc.

7
 CROATIA

Full speed
ahead
Below: Signing the contract for Aseptic filling
line 2. From right: Ivica Sertic, President of
Jamnica and Massimiliano Orsi, Regional
Manager Procomac.
Off the highway which connects Zagreb to Karlovac and driving
for several kilometers through small but very picturesque villa-
ges we reach the production facility of Jamnica, surrounded by
green pastures. Mr. Berislav Briški, Production Manager, welco-
mes us into the headquarters of Jamnica and starts telling us the
several developments that, among the years, made Jamnica the
biggest mineral and spring water manufacturer in the European
Southeast.
"The actual facility started to be built in February 2002, and after
only five months we started with water production", says Mr.
Briški.
In 2002 Jamnica decides to hit the market of the still beverages,
which means aseptic technology is now required. The company
realizes how many differences lay between traditional water fil-
ling lines and aseptic systems.
After examining important suppliers the choice is made for
Procomac. The contract is signed in November 2001, even befo-
re the new facility has been built. The delivery time is May 2002.
The workers rush in to have the building ready by the time the
line will be installed. The line is delivered on time, middle of May
as by contract.
"Procomac staff arrived on site and started the installation of the
aseptic line, managing everything with deep attention. We were
very impressed. We were used to have several suppliers for our
lines: specialized filler manufacturers for the filling bloc, process
companies to supply the syrup rooms, and others for the end of
line equipment. For the first time we had one single supplier
installing the whole line. Procomac staff showed a lot of sensiti-
vity towards us and our line operators while installing the line.
They managed and finished the installation process fast and
without any problems", explains Mr. Briški.
The start up of the line is divided in two phases: it is a compan-
y's priority to start water production as soon as possible, so the
aseptic line is initially used for still water filling. At the end of
September the line is definitely switched to aseptic in order to
finish the aseptic microbiological validation, which ends succes-

8

Integrated process systems for aseptic line.
sfully in December after filling
100.000 0.5lt bottles. At this point
aseptic production starts without
any problem.
ASEPTIC FILLING LINE
The heart of the line is the filling
bloc, were empty bottles come
through a system of Convair 2000
air conveyors by Procomac
Packaging. The filling bloc is com-
posed of two Procomac Gripstar
GX 1R: sterilizing and rinsing
systems with electronic control of
the treatment times. The filler is a
volumetric electronic Fillstar FX
with magnetic flowmeters and
comes from the long experienced
matured by Procomac in aseptic fil-
ling. There is no contact between
bottle and nozzle in order to gua-
rantee more safety for the product's
quality. This filler is characterized
by a neck handling system for the
Procomac aseptic bloc for line1.
management of the bottles. This
particular systems drastically
decreases the changeover down-
time because of the possibility to
easily handle any bottle format
as long as the neck finish stays
the same. Procomac also sup-
plied all the process units which
manage and control all fluids
necessary for the correct ope-
rating of the plant.
The end of the line equipment
was supplied by Procomac
Packaging and it is composed
of bottle and pack conveyors
and a low level palletizing
system Opera 1000.
"The installation of the aseptic Jamnica is located. The plant was destro-
line was very fast but at the
same time very accurate. Our
operators haven't had much
time to learn how to manage the
line, but Procomac's technicians
have been with us also after star-
A long story
From the smooth and gentle
hills of the Prigorje region
comes the natural water
Jamnica, named after the
homonymous spring where
the water flows from.
Already in the bronze age
there were records of the
Jamnica water; in fact in 1828
during the re-surrounding of
the spring two previous ancient
draining systems were found. In
1772 the Austrian Empress Maria
Teresa ordered some water analy-
sis to be done in the Jamnica
spring. The water was found so pure
that was included in the Register of
Mineral waters of the Austrian court.
To find the first bottle of Jamnica water
we need to go back to October 18th
1828. From this date on the water was
bottled for the Croatian and Slovenian
market. After several acquisitions in 1961
the company became part of
Agrokombinat of Zagreb. The August of
1978 sets an important step for Jamnica:
a new bottling plant was opened in
Jamnicka Kiselica. In that same year the
production facility reached the round num-
ber of 50 million liters of water bottled.
The devastation caused by the war in
Yugoslavia at the beginning of the '90s
reached also the Prigorje area where
yed by several bombs on the 7th of
October 1991. Production started again
only 2 years later, after repairing an old
production line. In 1994 the first comple-
te filling line for 1.5 and 1lt PET bottles
was installed. The company started
growing fast and in 1995 the new
labels and above all the new logo
were born.
The year 2002 represented the
achievement of an important goal:
the company started the produc-
tion of "Juicy Fruits" and "TO"
fruit juices This is also the year
when the first production of the
natural spring water Jana star-
ted. Only a year after bottling
Jana water, the company
decided to reach also the
market of the flavored
waters: in March of 2003
Jamnica started bottling its
lemon and strawberry/guava
aromatic waters.
In June 2005 an agreement
with Procomac has been
signed for the supply of a
second aseptic line for flavou-
red water and fruit based
drinks.
9
ting production, in order that our for the supply of a complete water
operators could learn how to run filling line by Procomac, to be
the line without any problems. installed next to the aseptic line.
Personally I must say I have very "When we signed the contract for
much appreciated the complete line 2, Jamnica was already eva-
integration of whole set of machi- luating the possibility of exporting
nes. It was the first time for us that its products to the United States of
we had only one supplier for the America. Our water is of very high
whole line, and this makes every- quality and it was listed by the
thing a lot easier to manage", says European Union in a selection of
Mr. Pleπtina. pure spring natural waters through
the Fresenius Institute. Jamnica
EXPORTING TO USA area is a reserved natural park and
At the beginning the aseptic line no industrial activities are allowed.
hosts also the water production, but This is a further guarantee of the Marinko Pleština, Aseptic Production
soon came the need of increasing pureness of our water and the Manager, Jamnica.
the production capability, and at the source lays 800 meters deep under
end, this brand new facility is not ground. Our biological laboratory,
planned to host only the aseptic which is attached to the medical ago. This old documentation, com-
production. This is why in June university of Zagreb, supplied us pared to most recent one, showed
2003 Jamnica signed the contract analysis of more than a century that the water never significantly
changed among the years. These
data assure the organoleptic cha-
racteristics and qualities of the
Jamnica water" affirms Mr. Briπki.
Thanks to the potentials of the pro-
duct, the company is now planning
ASEPTIC LINE 2 to export the JANA water into the
North American market. The goal is
to reach high level retail shops.
The aseptic line 2 gurantees a production speed of
The bottle formats exported to
22.400 b/h on 1,5/1,0/0,5/0,25 l with flat or sport caps. The North America will be 1 and 0.5lt
products handled are flavoured water, ice tea, still fruit based with both flat and sport cap. It is
drinks with and without pulps. also planned to export fruit juices.
The scope of supply includes air conveyors CONVAIR 2000, ste- The foreseen high volumes brought
rilizing/rinsing/filling bloc unit with sterilizer and rinser mod. to the decision of installing a third
water bottling line, Procomac
Gripstar Gx and filler mod. Fillstar FX100, all protected inside a supply of course, with the same
rigid microbiological isolator which avoids the use of a clean room. features as the second:
The process units for the fluid management are realized in a newly A system of Convair 2000 air con-
high integrated version. The scope of supply also includes a pro- veyors guarantees the feeding of
duct pasteuriser UNITHERM P and a mixer UNIMIX C MULTI. the empty bottles to the filling blocs
which host a Gripstar ACE 2R rin-
Furthermore bottle and pack conveyors link the filling bloc toge-
ser and a Fillstar SF-PET2 gravity
ther with the OPERA 2000 manufactured by Procomac filler. Bothe versions of the lines are
Packaging. "ultra-clean", which implies laminar

10
Above, left: end of line 2 and 3 with OPERA palletisers from Procomac Packaging. Above, right: Procomac Gripstar bottle
rinser. Below: ultra-clean filling bloc from line 2, some aseptically bottled products.
flows of sterile air and contamina-
tion control of the filling environ-
ment to guarantee the hygiene of
the product. Two systems of bottle
and pack conveyors feed the end
of line composed of two Opera
2000 low level palletizers. Line 3
has been commissioned during
June 2004.
"From May until the end of
September water production
usually goes full speed, with both
filling lines working. One is fully
dedicated to the 1 and 1.5lt format,
while the other manages the 0.5lt
and 0.25 lt bottles with both flat and
sport caps" says Mr Pleπtina.
NEW DESIGNS, NEW FLA-
VOURS
A very distinctive bottle design
makes Jamnica's products easy to
spot on the supermarkets' shelves.
But not only there, in fact, at the
last edition of the Aqua Expo in
Paris, Jamnica's glass bottle was
awarded the second prize for the
best bottle design with the 0.75 and
0.25lt bottles. Also the product itself
has received several awards: one
among all was the EAUSCAR
("oscar des eaux) for the best flavo-
red water that Jamnica received at
the 2004 Aqua Expo for its straw-
berry/guava aromatic water.
"We believe that flavoured water is
the main product in the future of the
water market. Our aromatic water
has a very low level of sugar, low
calories and no preservatives
added. This is the product that will
take the lead in the next years"
explains Mr. Briπki.
NEW GOALS AND EXPECTA-
TIONS
Jamnica's main goal is to increase
their presence on the local market
with both water and aseptic filled
beverages. There is also a high
possibility that the company will
soon hit also the market of the
functional drinks.
When asked how he feels about
Croatia entering the E.U., Mr. Briπki
very simply tells us that the hole
Agrokor Group is getting ready for
such a possibility. The challenges
and the competition will increase
drastically but the company is
ready to face this new adventure.
"It will be definitely positive for the
entire country if Croatia could enter
the E.U.There are several compa-
nies like Jamnica that could take
advantage of this opportunity",
says Mr. Briπki.
"We chose the best technological
solutions possible that could gua-
rantee a safe management of our
high quality products" says Mr.
Briπki and adds "After two years of
production we reached 75 million
liters of bottled product: 35 million
liters of aseptic beverages and 40
million liters of water. Very shortly
we will reach the magic number of
100 million liters".
TECHNOLOGY

PLUS
Line control software
“Procomac Stye”
PLUS line control software developed by Procomac ena-
bles one operator only to monitor and adjust all working
parameters of all machines of the line from one control
panel.
The control panel with touch screen monitor is installed
near the filling bloc; it is possible to control line producti-
vity, acknowledge line alarms, determine line efficiency
and forward all relevant data to company ERP software.
Procomac PLUS is a “software translation” of DIN 8782
regulations for the determination of line efficiency; it is
then easy for operators to spot critical line point and solve
them before they become an issue. Key line data are
represented on the screen using histograms. Data are
saved on a database at the end of each shift or at opera-
tor's request or at the end of each production batch.
PLUS is designed as a statistical analysis tool for real-
time or historical production data. This software can auto-
matically generate historical production trends that can
be interactively consulted in order to evacuate the pro-
duction and - if an inefficiency is spotted - can help deter-
mine the reasons.
Traceability of both raw materials and finished products is
built-in: all operations related to traceability can be prefor-
med according to Europeans norms. All data exchange is
performed through high speed data network to unload
each machine's PLC.

12
GERMANY
TROY AQUA
Bottling from source
Troy Aqua GmbH, a bottling company of
mineral water, was founded at the begin-
ning of 2002 in Jessen small town in the
North-East of Germany.
The company owns two water springs
where it extracts 70 million litres per hour.
Troy Aqua has a cutting edge productive
facility of about 40.000 sqm located in the
industrial area of Jessen. In January 2003
a new filling line started production with a
capacity of 25.000 bph with the 1.5lt for-
mat.
In spring 2004 Troy Aqua signed a con-
tract with Procomac for the supply of a
complete water filling line. Only a few
months later, thanks to the solid relations-
hip between the two companies Troy
Aqua ordered a second scope of supply:
a complete filling line, from the bottling to
the end of line equipment, entirely by
Procomac.
The filling bloc is composed of a rinser
and filler by Procomac. The rinser is a
Gripstar ACE 2P with double treatment
and penetrating nozzles. This particular
version of the rinser is characterized by
In spring 2004
Troy Aqua
signed a
contract with
Procomac for
the supply of a
complete water
filling line.
the system "no bottle no spray", that in
case the bottle isn't positioned properly
side the gripper, the rinser inhibits the
passage of ozonized water from the
nozzles.
The filler is a Fillstar PET2, characterized
with an extreme versatility and allows to
fill still and carbonated beverages with
very low changeover times.
This kind of isobaric filler fits perfectly to
multi-format plants: the number of parts
to replace for format changeover is very
low and no kind of carousel height adjust-
ment is necessary either.
There are laminar flows over the bloc that
allow to protect the product and the con-
tainers from contamination during the cri-
tical phases of production.
A system of air conveyors, Convair 2000
of Procomac Packaging, ensures the fee-
ding of empty bottles to the filling bloc,
while bottle conveyors and pack conve-
yors transfer the full bottles to the end of
line equipment, composed of a high level
palletiser AGILIS by Procomac
Packaging.
Troy Aqua logo .
13
 YST:
Procomac Technology
keeps convincing
the Chinese market

CHINA

YST, an important Chinese bottling Procomac mechanical counter-

company on the Chinese market,
has confirmed its trust in
Procomac technology. Following
the supply in the last years of three
complete hot fill lines at high speed
YST has chosen Procomac again
for a new "top performance" pro-
ject for filling still and carbonated
water.
pressure filling head is a reliable fil-
ling solution that requires almost
no maintenance. Bottle handling
through the neck ring allows a dra-
matical reduction of changeover
downtimes when using bottle with
the same neck finish.

The rinsing/filling bloc accordingly

supplied by Procomac guarantees
a speed of over 40.000 bottles per
hour in the formats 0.55 and 1.5 l.

Bottle rinsing is performed by a

Gripstar 1R 60 rinser coupled with
a mechanical counterpressure filler
model Fillstar PET2 120 fitted with
AROL 20 heads capper.

Procomac Fillstar PET2 counterpressure filler.

14

Cobecsa is a Spanish company located in Jaraba, about
150 km from Saragossa, that bottles still and carbonated
water and soft drinks. Cobecsa chooses Procomac tech-
nology for a versatile filling bloc. The hear of the Bloc Hal
M is the composed of a counterpressure filler Fillstar
SPAIN
Cobecsa
FILLSTAR M, that can treat both glass and PET bottles
and fill several kinds of products such as still and carbo-
nated water and soft drinks.
The filler can reach a productions speed of 20.000 bph
on the 0.33 lt format when bottling still water in PET bott-
les, 10.000 bph on the 1 lt glass bottle format for
soft drinks and 12.000 bph for 1 lt glass bottles
for carbonated water. Each production facility of
the Cobecsa Group is provided with a laboratory
for controlling products, packaging and raw
materials, to guarantee its customers the highest
quality.
Procomac mechanical counterpressure filler
FILLSTAR M foir glass and plastic bottles
15
 Short news
ITALY
Sancarlo Spinone
The company was founded in 1942 during World War II by two sisters Giuditta
and Carla Colombo, who had a kiosk for bottling and selling water. In 1953 this
small company from Bergamo became a society with the name of Fonti San
Carlo Spinone Spa.
The last 25 years the company has seen a continuous growth in terms of pro-
duction and also turnover: from the 20 million bottles a year of the first years to
the 141 million bottles of today.
The water San Carlo flows from the depth of the earth, originated from rain and
from the melting of the snow. In its long path along the earth stratums the water
mineralizes, gaining its peculiar characteristics.
The company bottles two different brands of water: Sancarlo Spinone and
Primula.During the last 25 years the company have increased their production
and turnover figures from 20 millions to over 141 millions of bottles per year.
The need to increase their production capability led the company to sign a con-
tract with Procomac for the supply of a filling bloc for both still and carbonated
water in PET bottles. The whole bloc was delivered in March 2005.
The filling bloc is composed of a Gripstar 2R 50.100.113 rinser, a Fillstar PET 2
60.10.113 filler and a capper from Arol (10T). The Fillstar PET 2 filler is part of
a range of isobaric fillers designed to satisfy the demands of a modern filling
line. The filler reaches a nominal speed of 17.000 bph of still water on 1.5lt size
and 15.000 bph with carbonated water on the same size.
With the 0.5lt format the filler can reach a speed of 20.000 bph with both still and
carbonated water, while with the 2lt bottles the filler reaches a speed of 13.300
bph of still water and 11.000 bph of carbonated water.

ITALY
Acqua Fontalba
The natural mineral water Fontalba flows at 1200 meters
and is bottled directly from the spring to guarantee the pro-
tection of the organoleptic qualities.
The Sicilian company, based in Montalbano Elicona, has
signed an order for the supply of a filling line for still and
carbonated water in glass containers.
The filling is handled by a monobloc HAL M 36.6.125 with
bottle base handling. The filler reaches a nominal speed of
10.000 bph with the 0.92lt bottle and 12.000 bph with the
0.5lt format. Together with the line Procomac supplied a
Unisat, dearation and saturation system.

16
 An old roman aqueduct

(Photo: Alison Scott)

ITALY
Fonte Capannelle
From the first Roman aqueduct built in
312 b.C. and for almost a century until
the Goths invasion that destroyed part
of the aqueducts, the city of Rome
could benefit of a water provision that
no other city had in these ancient
times, especially for quantity and qua-
lity of the water.
In its most marvellous period, Rome was served with 11 as medium mineral water, with therapeutical effects: the
aqueducts that supplied 13 cubic meters of water per water of Fonte Capannelle stimulates the gastric functio-
second. Six of them were passing through the Regional nalities as well as the hepatobiliary and digestive func-
Park of the Ancient Appia. The most important one was tions.
the Anio Vetus, built in 200 b.C., and proceeded for nearly During year 2005 the company signed an order to
all its way underground. Procomac for the supply of a bottling line for still and car-
In 1952, following some drilling operations made in order bonated water. The bloc is composed of a Gripstar 1F
to find water, a new spring was found in the Regional 50.100.113 rinser, a Fillstar PET2 60.15.113 filler and an
Park of the Ancient Appia. This is the date that marks the Arol 15T capper. The feeding of empty bottles to the bloc
beginning of the company Santa Maria at Capannelle. is guaranteed by a system of air conveyors, Convair
The water of this spring is characterised by important 2000, by Procomac Packaging, that also supplied full
organoleptic qualities, thanks to whom the Institute of bottle conveyors. The line reaches a speed of 15.000 bph
Hygiene of the University of Rome recognized this water on 1.5lt size.

ITALY
Terme di Brennero
The water Sanct Zacharias owes its name to Zacharias Geizkofler, who in 1606 restored the spring which had been
obstructed by landslides. Its peculiar characteristic, that made this water famous, is the depth of the spring: the water
flows about 1000 kilometres under ground and during its long and slow path of infiltration in the stratums it gains an
ideal mineralization.
The temperature of the spring is constant during the year around 22°C, which guarantees the firmness of its compo-
sition that determines a rare balance between its components and principal elements. Calcium, magnesium, sodium,
potassium, bicarbonate, sulfurate, CO2, and trace elements are all important components of the water Sanct
Zacharias.
This water is officially classified as hypothermal water, so with low mineral components.
In spring 2005 Procomac supplied to the company a complete filling line for bottling still and carbonated water in glass
bottles. The line is composed of a filling bloc with bottle base handling, a Fillstar M filler and a Gripstar 2R rinser. The
Fillstar M filler allows the maximum reliability with the highest performances. It is characterized of a high versatility: it
can fill both carbonated and still products. The bloc guarantees a speed of 10.000 bph with several kinds of formats
(1, 0.75, 0.5, 0.25lt).
The line is also composed of a Uniclean 3A, C.I.P. system with three tanks and a high level of automation; an Unisat
15, dearation and saturation unit with a capacity of 15.000 lt/hour; and an Ozosteril 15, system for the production and
mix of ozonized water used for bottle rinsing.

17
 Procomac Engenharia
Italian quality made
in Brasil
Procomac Engenharia
Ltda was established in
2000 to supply high qua-
lity sales and after sales
service for Procomac
customer in Central and
South America.
The Headquarters of Procomac
Engenharia in São Paulo, besides provi-
ding sales and after sales services, have
begun since 2003 the manufacturing acti-
vity for a series of rinsing/filling/capping
blocs designed in Italy: HAL series for still
and carbonated drinks in PET bottles,
MIR series for still and carbonated drinks
in glass and PET bottles and JUICE
series for hot filling of still drinks in glass
and PET bottles. Procomac Engenharia
can rely on a technical office of its own
and on a Manufacturing workshop with 12
technicians. Among the latest customer
that have chosen Procomac Engenharia
as a technical partner, two companies
stand out for their innovative range of
products in Mexico and Honduras:
Embotelladora Cactus and Embhosa.
Embotelladora Cactus de C.V. A
company always ahead of time and
ready to be the first one to offer inno-
vative solutions, Embotelladora
Cactus de C.V. trusted Procomac
Industries and their experience for
the supply of a filling bloc unit for still
and flavoured water.
Embotelladora Cactus de C.V. is a
Mexican company, founded in 1994
18
with the goal of bottling, distributing
and commercializing new products in
the beverage market. Today the com-
pany is leader of flavoured water
Mexican market, with a strong pre-
sence in the most important highway
restaurants and discount stores of
the country. In 1994 Embotelladora
Cactus was the first company in
Mexico to offer a water bottle with
sport cap. At the beginning of 1997
the company launched on the market
two versions of flavoured water:
Regular and Light. In 2001 a new
product is presented to the market,
especially thought for kids: Cactus
Kids.
In 2003 the packaging changed, and
new bottles are designed with very
innovative looks. In the same year
the company launches another new
product: Cactus Fitness, with 0 calo-
ries.
Always ahead of time and ready to
be the first one to offer innovative
solutions, Embotelladora Cactus has
chosen Procomac Industries for the
supply of a filling bloc for still and
flavoured water.
The bloc is a HAL SF PET filling

Above: internal view of Gripstar rinser inside a
HAL series bloc.
Right: Honduras is well-known
for the beauty of the seaside.
monobloc designed and built entirely
in Brazil by Procomac Engenharia.
The filler reaches a speed of 6.000
bph on the 1.5lt format and 10.000 on
the 0.6lt format with still water.
Embhosa, Embotelladora de
Honduras, S.A., is a new beverage
company located in North Honduras,
marvellous land of Central America
facing both Caribbean Sea between
Guatemala and Nicaragua and the
Pacific Ocean between El Salvador and
Nicaragua.
The company strategic market will ini-
tially be the area of the Atlantic coast,
but the future goals include an expan-
sion in the whole country. Embhosa will
be a new alternative for demanding
customers who desire to try new and
modern drinks.
To start this new adventure Embhosa
trusted Procomac's experience and
particularly Procomac Engenharia
which supplied a filling bloc HAL PET
1R designed and built in Brazil.
The bloc can fill both still and carbona-
ted water and soft drinks, reaching a
nominal speed of 12.000 bph with the
0.5lt format when bottling water (still or
Embotelladora
de Honduras
will be a new
alternative for
demanding
customers
who desire to
try new and
modern drinks.
carbonated) and 3.300 bph with the
2.0lt format when bottling soft drinks.
With this bloc Procomac Engenharia
reaches a number of 5 filling lines built
in Brazil and installed in South America
in only one year of activity.
The sixth, the seventh and the eighth
bloc, based on Procomac Fillstars SF
gravity filling head for still liquids, are
currently in construction for Salus
Uruguay, Danone Group (SF 24.24.6),
Nestlè Waters Brazil (SF 24.24.6) and
Nestlè Messico (SF 36.42.6). But this
is already another story, and we would
be glad to give you further information
in the next issue of PROCOMAC
TECHNOLOGIES...
19
MEXICO
At the end of the 30’s Pepsicola decided to
start a new adventure in the international
markets, and this is how the company arri-
ved in Mexico in 1938, actually in Mexicali,
capital of Baja California in the north-west of
Mexico. This city lays on the border bet-
ween Mexico and California, and it takes
the name from the first syllables of Mexico
and the first ones of California. In this period
the products' syrup used to come from New
York in small durmast casks, while the fla-
vourings were delivered in 0.5lt carboys.
In 1943 Pepsi founded a new sister com-
pany in Mexico with the name of PepsiCola
Mexican Syrup Company. The mission was
to distribute Pepsi Cola products on the
whole Mexican territory, taking advantage of
some local producers.
The first production plants were built in
Mexicali in 1938, then in Monterrey in 1942,
Mexico City and Guadalajara in 1943 and
Leone in 1945.
In 1947 Pepsi Cola built its first plant for the
production of syrup in
order to satisfy the
needs of the local
In the spring of 2005 the bottlers who were
third CSD filling line has growing fast.
The presence of
been shipped and commis- Pepsi-Cola on
sioned in the Veracruz the Mexican ter-
bottling facility. ritory has been
growing year
20
after year, building new plants in the whole
country. New production plants and the arri-
val of new products to launch on the market
made Pepsi one of the biggest beverage
distributors on the Mexican territory.
The mission of the company was to become
the best bottler and distributor of beverages
and water in order to satisfy the needs of
the Mexican consumers, guaranteeing the
highest quality of the bottled products, of the
technologies and of the production proces-
ses.
For this reason Pepsi always relied on effi-
cient suppliers, both for raw materials and
for production lines. This trust has been pla-
ced in the group Procomac Industries seve-
ral times, and particularly for the supply of
three complete filling lines for CSD.
In the spring of 2005 Procomac delivered
the third line for soft drinks that was instal-
led in the Veracruz plant.
Before the filling bloc an Unimix CM2, satu-
ration and mixing unit has been installed fro
product preparation, together with an
Uniclean 3B C.I.P. system.
Air conveyors Convair 2000 by Procomac
Packaging are used to feed empty bottles to
the filling bloc. Inside the bloc Procomac
has installed a Gripstar ACE (auto clean
execution) rinser mod. 2R 90. Gripstar ACE
is characterized by an extreme versatility:
the treatment times can be adjusted with a
simple operation; in this way it is possible to
optimize treatment times for each
bottle with significant savings in
terms of time and sterilizing solu-
tion.
The heart of the bloc is the Fillstar
PET 2 mechanical counterpressure
filler with 120 filling heads: this filler
can treat both still and carbonated
products with very fast changeover
times, thanks to the bottle neck
handling system.
The filling valve is characterized by
a very low number of pieces and
seals and by the total absence of
crevices and threads in contact with
the products. This system guaran-
tees a high quality of the finished
product.
Outside the bloc Procomac has
installed an innovative level, cap
and label inspector model
Checkstar. Functional connection
with the filling bloc allows supervi-
sion of operation of the filling heads
and the capping heads; statistical
data is recorded, and a line alarm is
issued in case of repeated rejec-
tions from the same capping head
or filling valve.
Checkstar can also automatically
manage all product
sampling operations:
bottle samples are with-
drawn and coded with
indication of filling valve
and capping head involved.
A system of bottle conveyors and
pack conveyors guarantees the fee-
ding to the end-of-line equipment,
composed by a high-speed, low-
level infeed palletizer OPERA 2000
ES; the low level feeding guaran-
tees an easy access to the layer for-
mation area.

CYPRUS
Christis Dairies Ltd.
The story of Christis Dairies Ltd of
Cyprus starts in 1961 as a company
in the milk pasteurisation and bott-
ling sector. During the last 40 years
this company has installed the most
innovative systems for the produc-
tion of milk, advanced technologies
for the bottling of milk, and has offe-
red to the market the widest range
of products ever produced in
Cyprus.
The Cyprian company became lea-
der of the local market in 1974 when
it expanded its production capacity
founding the new dairy division.
With this new division Christis
Dairies could satisfy the growing
demand of dairy products in the
local market, exploiting the local milk
production.
In 1985 the company moved to a
brand new production plant built in
the Industrial area of Ayios
Athanasions of Limassol, the
second biggest city of Cyprus facing
the Mediterranean Sea. This plant
has always been upgraded with new
technologies to guarantee the
highest level of quality of the pro-
ducts. Today this plant is one of the
most modern, efficient and environ-
ment friendly of the whole island.
Christis Dairies Ltd exports milk,
cheese and other dairy products in
several countries world wide. The
company has received the
"European Export Award" twice from
the Cyprian federation of Industrials
and the Ministry of Commerce, and
today it exports 50% of the entire
dairy production.
Procomac installed at Chrisitis
Dairies' plant in April 2005 a comple-
te fresh milk filling line for PET bott-
les.
A system of bulk bottle conveyors
feeds a Procomac unscrambler,
Topstar S 20/30, from which the air
conveyors Convair 2000 lead the
empty bottles to the filling bloc.
The bloc is composed of a Gripstar
1R rinser and a gravity filler HAL
SFL-PET, expressly designed for
milk filling.
The filler reaches a speed of 4.000
bph on the 1.5lt size, but the line will
also handle the 0.5lt bottle and in
the near future the 0.25lt bottle.
This order will also supply a system
of full bottle conveyors and pack
conveyors. With this important refe-
rence Procomac brings its techno-
logy for the first time on the wonder-
ful island of Cyprus.

21

UK
Whyte & Mackay
production
relies on five
distilleries
on the Scottish
Highlands
Wine and Spirits
new developments
WHYTE & MACKAY LTD. is a global
spirits company with significant core
brands, namely Whyte and Mackay
Scotch Whisky and The Dalmore
Single Highland Malt. The company is
also the world's leading supplier of
own label, private label and branded
Scotch Whisky.
With four malt distilleries and the only
grain distillery in the Highlands of
Scotland, Whyte and Mackay distils,
blends, bottles and packages Scotch
whisky and other spirits for many mar-
kets and customers around the world.
To increase its production capability
and to optimize its filling lines for
whisky in glass bottles Whyte and
Mackay has chosen Procomac as
strategic partner.
An agreement has been signed to
supply a new complete line for the fil-
ling of spirits with a production of
19.800 770 cc. bottles per hour;
moreover a spirits filling bloc with
double capper with a production of
13.200 700 cc. bottles per hour will
22
Whyte and Mackay Distilleries in Dalmore in the Scottish Highlands.
follow shortly.
The project is completed by an AGILIS
1000 high level infeed palletiser from
Procomac Packaging and a conveyor
system with a shuttle that will serve all
the filling lines in the bottling facility.
FORSTER’S WINE ESTATES
QUALITY WINES FROM AUSTRALIA
Foster's Wine Estates is one of the biggest wine companies worldwi-
de with prestigious labels such as Beringer, Lindemans, Wolf Blass,
Penfolds, Rosemount, Matua Valley, Wynns Coonawarra Summer and
Castle of Gull.
Procomac has been selected to supply two rinsing/filling blocs based
on the new FILLSTAR ADV 5.5, a counterpressure filler that features
fully automatic filling level adjustment and fully pneumatic filling valve
control.
The two blocs will be installed in Australia in the new bottling facility
that has been built next to the group wineyards in Nuriootpa in the
Barossa valley, 80 km. east of Adelaide.
The bloc 1 features a Gripstar ACE HS 84 rinser and a FILLSTAR ADV
M 100 filler that guarantees a production of 24.000 0.75 l. bph with still
wine and over 14.500 bph with sparkling wine. The bloc 2 features the
same Gripstar ACE HS 84 rinser and Fillstar ADV M 100 filler to achie-
ve the same performances. Both the blocs are fitted with double cap-
per to be able to manage different types of corks and they are desi-
gned for fast and efficient format changeover.

Above: FILLSTAR SF-M gravity filler for spi-
rits. Left: The cellar under Balvenie bottling
facility. Below left: Grant’s Family reserve.
WILLIAM GRANT & SONS LTD, for five
generations an independent family distiller,
was established in 1886 by William Grant.
Grant's now sells around 4 million cases of
whisky a year and is the world's fourth lar-
gest Scotch whisky brand after Diageo,
Allied Domecq and Pernod Ricard, with a a
market share of more than 10%.
The headquarters are in Strathclyde near
Glasgow.
William Grant & Sons was one of the first
distillers to see the potential market for
"single malt" whisky with the widely reco-
gnised "Glenfiddich" single malt whiskey.
Procomac has been one of Grant's sup-
pliers for many years; it has recently
signed a contract to supply a filling line for
whisky in glass bottles for a production of
William Grant
& Sons
is the biggest
of the few
family
distillers
in Scotland.
12.000 bph.
The line has been designed for the maxi-
mum versatility in terms of use of different
bottle formats: 350 ml, 375 ml, 700 ml, 750
ml and 1000 ml in the traditional triangular
form that characterizes a good part of the
Grant's whiskey production
The feeding of the line is handled by
RESOLVIS low-level outfeed depalletiser
supplied by Procomac packaging.
A GRIPSTAR " product Rinser" is deployed
to rinser the internal surface of the bottle.
A Fillstar SF-M gravity filler for spirits gua-
rantees the maximum fill level precision
thanks to a low-vacuum fill level correction
system.
23
 Packaging
Technology
“Analysing
how much a
plant is worth
evaluating the
suppliers
does not
necessarily
mean finding
out the lowest
price”.
Mr. Capetta, what kind of guidelines
An Interview does Barilla normally follow to evalua-
with Daniele te a supplier?
Capetta, The potential supplier has to cope with
the stringent requirement that our pur-
Purchasing chasing managers have studied. The
Director for suppliers are preventively selected
production according to the market segment in
lines and which operate. Our department can rely
on engineering competences, consolida-
buildings, ted in at least 10 years of working expe-
Barilla G. & R. rience inside Barilla. When we begin a
new project a very important parameter
that directs the following choices is the
determination of the value of the plant.
This value allows us to calculate - toge-
ther with the colleagues of the enginee-
ring Dept. - the budget of the project, its
criticality and its strategic value.
After determining these values we can
select the market segment where the
potential suppliers operate, we ask for
quotations and we subsequently analyze
them. The supplier will have to guaran-
tee:
- observance of Barilla technical guideli-
nes;
- high levels of automation and flexibility;
- hygienic safety to obtain a high-quality
product;
- innovation (greater potential of develop-
ment);
- attention to maintenance costs;
- unification and standardization of the
components;
- attention to energy saving.
The financial status of the supplier is also
attentively monitored.
I would like to underline that analysing
how much a plant is worth does not
necessarily mean finding out the lowest
24
price. The detailed analysis completed
by our division for every new project
judges its correct value in terms of
machine quality, price, reduction of
running costs, simplification of the ope-
rational activity. For instance our
Bakery Division uses 37 different pro-
duction technologies; every 3 years
each product is improved by modifying
its recipe. This is why Barilla produc-
tion lines are designed with flexibility,
automation and innovation in mind.
These are the kind of considerations
that matter in determining the value of
a new project.
Among the criteria of selection of
the suppliers you also mentioned
energy saving…
I noticed in the last 5 years an increa-
sing attention for the energy saving of
process plants and production plants,
not only for their impact on the running
costs, but also for the environmental
implications that derive from their use.
What preferences does Barilla have
as regards the geographical origin
of the suppliers?
The production of Barilla covers the
whole European market and the
American market; for Barilla G&R
Europe is a domestic market and all
the European suppliers of production
plants are considered "domestic sup-
pliers."
From the privileged observatory
represented by the Purchasing Dept
of Barilla what kind of evolution
have you noticed in the technologi-
 Daniele Capetta, Purchasing Director
for production lines and buildings,
Barilla G. & R.

cal offer of the food production plants in the last

10 years?
As regards the process plants the offer is a static
one; I don't remember breakthrough innovations, but
only refining touches and optimizations (for example
putting electronic controls and automations on exi-
sting plants). As regards the packaging in our field of
activity I noticed that on the most important markets
an evolution has taken place from electro-mechani-
cal machines to electronic-controlled machines,
although in many areas - notably Eastern Europe -
most machines are still mechanically controlled.
Working with great numbers, Barilla tends to adopt
traditional end-of-line with palletisers. Robot palleti-
sing solutions have primarily been used for new pro-
duction facilities, where it is possible to optimize the after sales service is important in your opinion?
line layout for their use. The after sales assistance is fundamental, both for
Working with big numbers also means that the lines maintenance interventions and for line upgrades
are normally used for a single package format and and modifications. Barilla operates with its suppliers
frequent package changeovers are not required. in co-design: the competences of both are used to
When we periodically launch new advertising cam- find out the best solutions and to improve them.
paigns on the market using "display" pallets we use Considering that the obsolescence of an end-of-line
dedicated lines. in our sector is very slow (up to 20 years) the main-
Our attention is thus focused on obtaining high effi- tenance is very important to guarantee the reliabi-
ciency lines with simple operating and maintenance lity. Barilla is internally structured to perform pro-
procedures using traditional palletising solutions. grammed maintenance interventions on all its pro-

The advent of electronic controls has pushed

the development of production lines that interfa-
ce directly with the warehouse, with invoicing
Dept, with raw materials purchasing Dept. Their
control software is directly connected with
Company's ERP software and exchanges data
on a real time basis. What is your evaluation of
such systems?
The integration and fast data exchange among the
different Departments of a Company like Barilla is
fundamental. I believe that, while the mechanical
technology of the production plants is substantially
mature, the management of the information and the
functional integration are very important innovations
for the next future. Barilla can control the whole pro-
duction process from the field of wheat to the small
retail shop; therefore it is in very important to facilita-
te the exchange of information to optimize all activi-
ties involved. For example: for a long time now
Barilla has been using a software system that allows
advance planning of line production from a minimum
of 3 days to 10 days. In this way we are able to work
in" just in time", without warehousing, with both raw
materials and packages.
The ability of a supplier to perform high-quality
Barilla was founded by Pietro Barilla in 1877 in Parma,
more than 125 years ago, as a bread and pasta shop.
Today it is Italy's largest food-processing industry, arti-
culated into 29 production plants, with direct control
over 10 mills supplying 70% of raw material require-
ments. The firm, with a 2004 turnover of 4,68 billion
Euro and 7321 employees, is led by the Barilla Family.
Barilla is undisputedly the leading name in pasta in
Italy and throughout the world. It is the premier Italian
group for baked products (not to mention pasta sau-
ces) and third in Europe with the brands Mulino Bianco,
Pavesi and Wasa. Barilla food production is based on
three principles: product quality, attention to nutritio-
nally-balanced eating and of course flavour.
Every year Barilla uses over 1.250.000 tons of hard
wheat, 350.000 tons of tender wheat, 500.000.000 of
eggs, 1.442.000 of tons of other ingredients for the pro-
duction of over 600 products commercialized under 12
different labels. Over 9.000.000.000 of pasta's dishes a
year are prepared with Barilla products.
 SELLA
duction lines but I believe that for new production facilities
signing an agreement for programmed maintenance interven-
tions directly with the supplier can be an option to consider.
tradition
Can you tell us something about your experience with Mr. Morreale, please could you tell
Procomac Packaging? us about the main events of this
The collaboration with Procomac Packaging has begun at the historic brand of the Italian wine
end of 2002 with the supply of two robot palletising systems and industry that nowadays belongs
handling systems for the Barilla production facility of Ames, to CAMPARI, one of the most
Iowa in the United States. important groups in the
Following the guidelines I mentioned before, we chose International scene?
Procomac Packaging because all selection criteria for a Barilla Company Sella & Mosca was esta-
supplier were met. blished in 1899 in Alghero, Sardinia
The positive results of this first plant and of the others we made by 2 cousins from Piedmont
together with Procomac Packaging are also the result of the (Northern Italia); they drained the
constant exchange of information between Barilla Engineering marshy areas, developing a 600 hec-
Dept and Procomac Packaging technical office: I believe this tares estate into an agricultural villa-
exchange of information has been beneficial for both compa- ge producing citruses, vegetables
nies. and vines.
Our primary objective has always been to furnish a quality pro- In the early 50's Sella & Mosca star-
duct to our customers (quality of the product is paramount for ted the production of wines for the
Barilla); it is then necessary to use highly selected raw materials local market. In the late 50's they
and cutting-edge technology for the production plant. The fact moved the filling activity to the cur-
that Procomac Packaging has demonstrated the same attention rent site - I Piani - and started the
to its customers and the good relationship between our compa- production of "Coral Rosato" a sweet
nies have surely been conclusive factors to renew the trust in and sparkling rosé wine of fairly
Procomac Packaging as partner for two important plants that good quality.
are now in the commissioning stage, one for the Barilla produc- But it was only in 1976, when the
tion facility in Rubbiano (Parma) and one for the Pavesi produc- company was bought by Bassetti
tion facility in Novara. first and Bonomi later, that Sella &
Mosca started the production on a
bigger scale. Some of the most
important selections of white wines
such as Torbato, Terre Bianche,
Vermentino La Cala, were created,
that also today are very much appre-
ciated.
After this first results with white
Established in 1997 as "packaging division" of Procomac
wines the company focused its atten-
Industries, Procomac Packaging has experienced a continuous
tion to the red wines, using grapes
growth: nowadays it has reached a compete operational auto-
like Merlot, Cabernet, Cannonau and
nomy.
Carignano, creating the well-known
During the last years, by deploying the long technical experience
Marchese di Villa Marina, Raim,
of its dedicated staff, Procomac Packaging has introduced a com-
Tancafarra, Terre Rare Doc. Medeus
plete and innovative range of palletising and depalletising systems
is the latest of those red wines.
(traditional and robotic-based) and has developed handling
A careful and peculiar handling is
systems for the most stringent handling requirements.
reserved to Anghelu Ruju, a "medita-
This outstanding design capability has established Procomac pac-
tion wine" , produced exlusively from
kaging as a reference company not only in the Beverage business
Cannonau grapes: bunches are col-
- although Beverage still accounts for more than half of the total
lected very late, are placed on mats,
turnover of the company - but also in the mainstream food busi-
protected from the night humidity,
ness.
and turned by hand at irregular inter-
To date, Procomac Packaging has commissioned 38 robot-based
vals according to the environmental
palletising and depalletising systems and 87 traditional palettising
temperatures and other features.
and depalletising systems, which have gained to Procomac pac-
Anghelu Ruju requires very particu-
kaging the status of one of the most qualified manufacturing com-
larly favourable conditions and it is
panies in the food and beverage machinery sector.
produced only in the best years.
Sella & Mosca was always receptive

& MOSCA:
and innovation
to technology innovation: for exam-
ple and for over 20 years now the
fermentation of all wines has been
carried out under controlled tempe-
rature, with a cellar conditioning
system controlled by computer.
How important is the filling tech-
nology for Sella & Mosca?
A production company with foresight
should always invest in the technolo-
gical innovation: the existing filling
line has been recently renewed and
updated both concerning the produc-
tion and layout aspects. Further to
the new filling/capping bloc a new
low level outfeed depalettiser, sup-
plied by Procomac, has been instal-
led, together with new bottle conve-
yors integrated with a synchroniza-
tion system. This year a new end-of-
line system from Procomac with a
high-level infeed palletizer will be
placed.
These new systems are paramount
to optimize the production flow,
making the optimum use of each
machine, and lowering the noise
level of the whole line: today thanks
to Procomac we have reached a
noise level under 80 dB.
The goal we set for the new palleti-
zer is to simplify operator's interven-
tions and speed up format changeo-
ver operations, as this line works
with 13 types of carton packages
featuring different labels.
How do you evaluate the service
activity of Procomac Packaging?
Positively. Sella & Mosca can rely
upon has very highly-skilled internal
staff, and by co-operating with tech-
nical staff of Procomac Packaging
we could reach important goals: for
example we have optimized restar-
ting procedures of the line in case of
stops. Recently a remote control
system has been installed on the line
to shorten up intervention times in
case of line stops.
What about future developments
and how is 2005 harvest going to
Interview with
Giuseppe Morreale,
Plant Director,
Sella & Mosca Spa.
Sella & Mosca, a primary
wine Company within
be? Campari Group, has cho-
Sella & Mosca is an open-minded sen Procomac packaging
company which reserves great to supply of a low-level
importance to marketing and com- empty glass bottles
munication: for over 15 years we depalletiser.
have been organizing visits to our They recently renewed
cellars with tasting of wine and local their trust in Procomac
food. The old farmers' structures Packaging with the order
have been restructured at the end of of a high-level infeed
the 80's the two Villas of the first 2 palletiser AGILIS 1000.
owners'. The line can treat cartons
We will go on "cuddling" our visitors of glass bottles in various
who normally become also custo- formats.
mers.
From the technology point of view
we will continue improving the pro-
duction line. Recently a new cellar
has been built up for small produc-
tions of high -quality wines with a
new control system for barrels humi-
dity and temperature. A further deve-
lopment will be the automatisation of
a small packing line for export orders
with special packages (Japan,
Brazil).
As regards the grape harvest 2005, I
prefer not to express forecasts,
since a good season depends on
many factors: nowadays the grape
collection is not carried out as it was
before: it is fully automated thanks to
a long-time experience; anyway a
small hailstorm can still destroy the
work of an entire year.
Some references among the range
of products of Sella & Mosca.