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Food & beverage manufacturingManufacturing & robotics

Bellini Foods — Aseptic Bottling Line 3

A 24 000 bottles/hour aseptic PET line: blow moulding, aseptic filling, capping, labelling, case packing and palletising, with live OEE on every machine and its own utilities and CIP block.

DjiniousCCOperations & SCADA
DjiniousCC
The Bellini Foods bottling line overview in DjiniousCC: blow moulder, conveyors, aseptic filler, capper, labeller, case packer and palletiser in a single left-to-right train, each machine showing live OEE.
site code
BLN3site code
assets
12assets
live tags
95live tags
authority class
C4authority classoperational action

Site BLN3, Parma, Italy. These are not mock-ups: all five sites run side by side in the same DjiniousCC instance — 99 assets and 693 live tags, acquired at 1 Hz, historised, alarmed, and each with a procedure that has been dry-run and proven on an isolated twin.

Chasing output past the quality knee costs more than it makes

Push the line to 100 % of the filler's nameplate rate and fill-level and seal rejects climb past 9 %. The extra bottles produced never cover the bottles scrapped, and on an aseptic line a reject excursion is a food-safety review, not just a yield number.

What the platform models here

Each family has a behavioural model that the live simulator and the proving twin share, so a dry-run behaves the way the plant does.

Blow moulder · Aseptic filler · Capper · Labeller · Case packer · Palletiser · Accumulation conveyors · Plant air · CIP & syrup tanks

The procedure: Line 3 Overspeed Reject Recovery

Bring the aseptic filler back inside its quality window after an overspeed push: trim the filler and the machines either side of it back to the balanced line rate, and require line-supervisor confirmation before the change is applied. Authority class: C4 · operational action.

  1. Step 1

    Trim filler → 86 %

  2. Step 2

    Trim capper → 86 %

  3. Step 3

    Trim labeller → 86 %

  4. Step 4

    Line-supervisor confirmation

  5. Step 5

    Notify line office

The proof: Filler Overspeed Push

The line is pushed to 100 % of the filler's nameplate rate to chase output; the machine runs beyond its quality knee.

Baseline — without the procedure

  • Filler reject rate ≤ 3.5 % — measured 9.40 %
  • Filler OEE ≥ 65 % — measured 75.3 %

With the procedure — every assertion holds

  • Filler reject rate ≤ 3.5 % — measured 1.90 %
  • Filler OEE ≥ 65 % — measured 70.1 %

OEE drops five points and rejects fall by a factor of five. The dry-run shows the operator that trade before the line is touched.

What the control room sees

DjiniousCC
The DjiniousCC operator dashboard scoped to the bottling line, with OEE trends for the filler, capper and labeller.
Three machines' OEE on one axis. The constraint machine is obvious without opening a report.
DjiniousCC
The DjiniousCC simulation page showing baseline and with-process dry-runs across all five sites.
Same proving ground, same isolation guarantee, whatever the plant makes.

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