Filling, Capping and Labelling Line For Ice-Cream Farm, Yorvale, UK

The Challenge:

One of the key challenges with this project was that due to the products being dairy based and for the food industry. Karmelle needed to supply a line that would be able to adhere to strict hygiene standards. This meant it needed to and be easily accessible and easy to strip down and clean as necessary. The line would also need to be able to deal with at least two different sizes of bottes. Karmelle’s design team worked with Yorvale to come up with a design that would ensure their ability to meet demand without any compromise on their quality.

The Solution:

Karmelle’s team designed and manufactured a complete line solution. This solution was made up of a bottle wash, filler, capper and labeller. The line started with a Karmelle, linear, air rinse machine which purges bottle with air before feeding them onto the filler. Next the four-head flow meter inline filler can fill both the 230ml and 500ml bottles with precision. This filling machine provides a hygienic and quick-strip solution.

Next the three-head, rotary, screw capping machine sorts and raises caps via a 25-litre cap elevator, before placing and screwing them onto the filled bottles. This bespoke machine features a ‘no cap’ detector with warning light for added piece of mind. Finally a three-point wraparound labeller automatically applies labels, before an integrated hot-foil coder prints best before/expiry dates/batch numbers onto bottles.

The equipment was installed at Yorvale by Karmelle in a custom-built production room on the brand’s farm. Since its installation, Karmelle’s engineers have added two new filling heads to help it meet the demand for its Kefir. The line is now running at 60 bottles per minute.