Most requested upgrades: Daniele Milesi, BBM Service Manager, speaks
In recent years, BBM has recorded a significant increase in requests for upgrades for bottling and packaging machines. These are interventions that improve the performance, safety, and efficiency of blow moulders, fillers, and packaging machines. We asked Daniele Milesi, BBM Service Manager, to tell us which are the five most requested upgrades and why they really make a difference for customers.
1. Steel mesh oven chain – one of the most requested upgrades
Daniele Milesi: «It is undoubtedly one of the upgrades most requested by our customers. It involves installing the steel mesh chain on the shrink tunnel, replacing the fiberglass bars. It is a modification we have installed on a large number of shrink wrappers — SMI and ACMI first and foremost — and which today represents almost a BBM standard.»
Main advantages:
- Better hot air ventilation and a reduction of about 10°C in operating temperature, resulting in energy savings;
- Increased shrink speed, thanks to greater airflow over the bundle;
- Greater mechanical strength and reduced wear of components, with a longer service life;
- Lower long-term operating costs.
«This upgrade has become a must for all machines revamped in our showroom in Lenna. When we want to deliver a “super luxury” system, the steel mesh chain is always included. One case I remember well is Knjaz Milos, a long-standing customer in the water and beverage sector. After the replacement, an old 2001 SMI SK 60F shrink wrapper went back to work with clearly superior performance.»
2. Inverter replacement: preventing downtime and improving safety – most requested upgrades
Daniele Milesi: «Inverters are key components in regulating the speed of electric motors, but unfortunately many of those installed on older lines are now obsolete. We intervene with a complete electrical system upgrade, replacing inverters and motors with new-generation, commercially available models and integrating them into the system in a safe and up-to-date way.»
Benefits of inverter replacement:
- Prevention of downtime caused by sudden failures;
- Greater safety: inverters are installed in protected electrical cabinets, shielded from dust and moisture, avoiding risks of electric shock and wear;
- Advanced software integration with the control system, enabling more efficient management from the HMI panel.
«Many customers contact us after experiencing unexpected downtime precisely due to an outdated inverter. Today, thanks to our interventions, they can operate safely and without interruptions. It is an investment that pays for itself immediately.»
3. Siemens PLC migration from S5 to S7: operational continuity and remote assistance
Daniele Milesi: «Many packaging lines are still equipped with old Siemens S5 PLCs, which are now out of production. To avoid compatibility issues and spare parts shortages, we propose a complete migration to the Siemens S7 system, with the addition of a touch HMI operator panel that acts as an intuitive interface between the operator and the machine.»
Main benefits:
- Definitive elimination of the problem of obsolete components;
- Modern, user-friendly operator interface with clear commands and updated graphics;
- Possibility of remote assistance;
«The upgrade also makes it possible to anticipate potential electrical failures: the new PLC detects anomalies and allows us to intervene immediately, before a machine stoppage occurs.»
4. SIDEL Matrix blower valves: simplified maintenance
Daniele Milesi: «On the SIDEL Matrix blower we have internally developed a special cover that solves a very common problem: the complex maintenance of the valve group.
Previously, the technician was forced to completely dismantle valves and pre-wired cables, with the risk of damaging them. Now, thanks to our solution, this is no longer necessary.»
The result:
- No more complete disassembly of pilot valves;
- Faster, safer, and error-free maintenance;
5. Automated product infeed channeling system
Daniele Milesi: We have developed a new mobile product infeed system that allows handling bottles with or without nitrogen. The upgrade introduces a revolution counter for quick and optimized format changeovers, improving line efficiency and flexibility. Previously, the infeed conveyor used a quincunx system to divide bottles (for example from 2 to 1 lane or from 3 to 2) and channel them towards the machine. However, with the introduction of new materials and reduced bottle weight, these old channeling systems tended to create slowdowns and instability during the process. To solve this issue, we designed a system based on a conveyor paired with an open side guide, which reduces pressure between bottles and positions them correctly in the most suitable direction of travel for the selected packaging type. In this way, bottles flow smoothly, without impacts or misalignment, ensuring a more stable and continuous infeed into the system.
We have installed it, among others, on lines for Terme di Crodo (PET line), Spumador Recoaro (PET line), Coca Cola Marcianise (GLASS line), Waldequelle (PET line), Coca Cola Nogara (Glass line) with excellent results: fewer stoppages, smoother infeed, and higher productivity.»
6. Most requested upgrades for processing asymmetric trays: flexibility and time savings
Daniele Milesi: «Another of the most requested upgrades concerns shrink wrappers that need to handle asymmetric trays. In these cases, the carton tends not to be centered with respect to the machine: without a structural modification, format changeovers can become very long and complex.»
The BBM solution:
The upgrade includes a series of mechanical adjustments and dedicated adaptations that allow precise operation even with asymmetric trays. The result is a significant reduction in format changeover time and greater stability during the packaging phase.
«We have installed this upgrade on several lines, also for TOP BRAND customers such as Consorzio Casalasco del Pomodoro and Menz & Gasser of Trento,” Milesi explains, “with excellent results in terms of efficiency and production continuity. It is an intervention we recommend to those who work with many types of packaging.»
Universal advice: from prevention to control
To conclude, beyond targeted upgrades, are there interventions or best practices you would universally recommend, regardless of the type of line?
Absolutely yes. Prevention is our best ally.
- Scheduled maintenance: Never neglect constant lubrication of the oven chain and blow molding carousel, and always respect periodic inspection cycles (weekly, monthly, semi-annual).
- Safety on palletizers: I always recommend installing the parachute system. In the event of a power failure, this device locks the platform, ensuring full compliance with the latest safety regulations.
- Filler regeneration: We offer ultrasonic cleaning to regenerate the steel parts of fillers, completely removing limescale. This is a service that can also be provided on a rental basis, with one of our specialized technicians.
With scheduled maintenance and the right upgrades, there is no need to “run for cover” in emergency situations. In our sector, prevention really makes the difference between efficiency and operational downtime.
