An ambitious project that blends history, innovation, and environmental respect, bringing the production efficiency of an iconic brand to new heights through the supply and installation of two “hybrid” PET and Glass bottling lines
A strategic synergy at the heart of the Italian beverage industry
We are proud to announce the completion of a large-scale project: the supply and installation of two complete bottling and packaging lines – one for PET and one for Glass. An operation that not only meets the production needs of a prestigious client but also highlights a strong commitment to sustainability and the circular economy, proving that excellence can be achieved through smart and environmentally conscious choices.
Acqua Fiuggi, eight centuries of wellness and innovation
Acqua Fiuggi is not just a brand; it is an Italian heritage. With nearly eight centuries of history, this oligomineral water, renowned worldwide for its unique health benefits, represents a symbol of wellness, elegance, and quality. Bottled at the historic Fiuggi plant, it has earned the trust and delight of generations, becoming a staple in the most prestigious hotels and restaurants.
Recently, Acqua Fiuggi embarked on a renewal journey, culminating in its acquisition by the family office of Leonardo Maria Del Vecchio (LMDV Capital). This new chapter aims to project the brand into the future, strengthening its global positioning while staying true to its roots. A key element of this vision is a strong commitment to sustainability: from the use of recycled packaging to investments in cutting-edge technologies to reduce environmental impact, such as photovoltaic systems and efficient production processes. It is within this context of renewal and environmental focus that our collaboration was born.
The BBM bottling line project
The dialogue with Acqua Fiuggi began in September 2023. The requirement was clear: to implement a high-performance PET line and a high-performance glass line. Our response, aligned with our philosophy and the market’s growing sustainability demands, was to propose hybrid solutions – combining both new machines and top-quality overhauled used equipment available from our facilities. After a careful design and consultation phase, we defined the supply:
16,000 bph PET Line: Designed for maximum flexibility, this line handles five distinct formats, covering both the retail market (the “Everyday” model in 500ml and 1000ml formats) and the HORECA sector (the “Premium” model in 330ml, 750ml, and 1000ml formats), for still and sparkling water. The line includes:
- Blow Moulder: SIDEL SB012 Series 2
- Filler: PROCOMAC Gripstar, integrated with UNICOM BBM for optimal performance
- Capping: A new AROL capper, developed in collaboration to handle tethered caps as well, with a downstream cap/level inspection unit
- Bottle Drying
- Labelling: A new PE Labellers machine
- Packing: SMI SK 50 shrink-wrapper (fully overhauled with BBM electronics), COMAG H70 handle applicator, the customer’s TMG palletizer relocated to a new position, ROBOPAC stretch wrapper, and PROCOMAC saturator
- Control: Implementation of our updated LINE CONTROL 2025 system, an advanced remote production monitoring solution
- Future Proof: A SMIPACK overwrapping machine will soon be added to package four 3×2 bundles together
Project Timeline
The project for Acqua Fiuggi took shape in record time: confirmed at the end of June 2024, it involved all the key phases of a complex operation, from machinery overhaul to the start-up of the new lines.
In July 2024, once the supply details were defined, BBM began refurbishing the machines in Lenna according to the customer’s specific requirements. The work was completed in November, making it possible to transport the equipment to the production site, located 700 km away.
Among the project’s biggest challenges, BBM successfully handled the exceptional transport of the two lines’ machinery. Five exceptional transports and twelve standard trucks were needed to move key components like the SIDEL SBO 12 S2 blow moulder, the Procomac filler, and the Simonazzi glass line. Some loads reached 4.5 meters in width and weighed over 63 tons, requiring special permits, dedicated equipment such as the BBM overhead crane, and precise logistical planning. All was carried out in partnership with specialized providers, ensuring safety, accuracy, and punctuality.
In September 2024, dismantling of the old lines officially began. The customer prepared the necessary infrastructure, allowing BBM to begin installing the PET line in November and the glass line in December.
Production start-up happened in extremely short timeframes: the PET line was operational by early February 2025, followed by the glass line at the end of the month. This result was made possible thanks to the ongoing dedication of a 12–15 member BBM team, specifically selected to cover each phase of the project. Each technician was chosen for their expertise in specific processes, machines, or brands (such as SIDEL, Procomac, Simonazzi), creating a complete and highly skilled task force. The team worked in perfect synergy on-site, supported by a key design optimization: relocating the depalletizing and end-of-line areas to the warehouse eliminated forklift traffic in operating zones, increasing safety and overall efficiency.
Remote control of the PET line in Fiuggi with BBM Line Control, as explained by Stefano Bonzi, BBM Project Site Manager for FIUGGI
BBM Line Control is an advanced real-time production monitoring and analysis system, designed to improve the efficiency of bottling and packaging lines. It collects key data such as the number of bottles produced, current machine status (production, pause, or alarm), and generates detailed statistics divided into the three work shifts (6:00–14:00, 14:00–22:00, 22:00–6:00). This information is displayed in a dedicated dashboard, accessible remotely, allowing users to identify machines with frequent stops, plan targeted maintenance, and analyze any operational issues. The system is compatible with machines from any manufacturer and can be installed even on plants without PLCs. Installation and configuration typically take 2–3 days per machine. Customer feedback has been positive: one of the main benefits highlighted is that production managers can monitor the entire plant virtually from home, gaining greater control and responsiveness in daily operations.
GLASS line – 20,000 bph: A high-efficiency NRB (non-returnable glass) line designed to handle both the classic FIUGGI Heritage formats (1000ml) and the new HORECA Luxury formats (250ml, 500ml, 750ml, 1000ml). The configuration includes:
- Line Start: Depalletizer already present and relocated
- BBM conveyor belts
- HEUFT bottle integrity inspector refurbished
- Filling and Capping: SIMONAZZI saturator, SIMONAZZI filler, AROL capper stand-alone.
- Quality Control: HEUFT cap/level inspector new, OCME checkweigher new downstream of the cartoner
- Conveyor belts used-refurbished and new
- Labeler, palletizer, shrink wrapper and cartoner already owned by the customer and relocated.
- Innovation: A quick format change upgrade was installed on the filler, with adjustable guides that minimize machine downtime – a key benefit given the format variety.
Sustainability and Added Value
Acqua Fiuggi’s decision to rely on BBM for partly used-refurbished solutions is a concrete demonstration of how the circular economy can be successfully applied even to large-scale industrial projects. Regenerating high-end machinery means:
- Reducing environmental impact: Less consumption of raw materials and energy compared to manufacturing new machines.
- Reducing waste: Giving new life to high-performing machines, avoiding disposal.
- Optimizing investment
For Acqua Fiuggi, the result is tangible: more efficient, faster, automated, and flexible lines, able to support the brand’s growth and renewal, all achieved in a short time and with a focus on sustainability. For us, this project is not only a technical and commercial success but also confirmation that the future of the industry lies in the ability to regenerate value while innovating with respect for resources and history. We are proud to have contributed to writing a new chapter in the history of an Italian excellence like Acqua Fiuggi.
Find out more about the project’s exceptional transports: BBM Exceptional Transport
Discover more about our solutions: BBM Products
Interview with Dr. Luigi Mascellaro, CEO of Acqua Fiuggi
What led you to choose hybrid systems for this project? It was almost a necessary choice because both lines, prior to our involvement, had already undergone some upgrades, especially the glass production line, and there was no need to fully replace both lines. In any case, almost 80% of the production lines are new.
How would you describe your collaboration with BBM throughout the various phases of the project, from initial design to production start-up? We worked hand in hand, barely perceiving a customer/supplier relationship.
Did the adherence to timelines and the commissioning of the lines meet your expectations? Originally, no, due to delays with other suppliers. We greatly appreciated BBM’s coordination and project management skills, support, production ramp-up, and commissioning, which they provided actively in the field alongside the Acqua e Terme Fiuggi team, operating as one team. Today, the lines perform as originally expected, and we are satisfied.
Are there already plans for further investments or expansion and innovation projects for the production plants in the coming years? Yes. We aim to increase production yield and raise the level of automation and technology in the end-of-line sections of existing production lines, and we are evaluating the installation of an additional production line to meet the growing order volume and expand our product range.
Based on this experience, would you recommend BBM as a partner for complex turnkey projects? Why? Absolutely! BBM is synonymous with reliability and flexibility.
