Beverage manufacturer Alita has installed seven Qimarox palletizing machines at its plant in Lithuania. With these Highrunner HR10 machines, capable of handling over one hundred pallets per hour, the company can produce 20 percent more wines, cognacs, whiskeys, and other alcoholic beverages. The palletizing machines are part of a completely new end-of-line packaging system, realized by Lithuanian system integrator INNA.
Since its founding in 1963, Alita has grown into an internationally renowned producer of alcoholic beverages. From Alytus, a city in southern Lithuania, the company produces and distributes sparkling wines, cognacs, whiskeys, and mixed drinks under brand names such as Alita, Santa Verona, Imperial XII, and Forum. In 2023, Alita produced no less than 20 million liters of beverages, bottled in 44 million bottles.
To create the conditions for further growth, Alita – part of the MV Group since 2014 – invested approximately 2 million euros in 7 new end-of-line packaging systems, including seven palletizing systems. The company enlisted the help of INNA, the Lithuanian system integrator with years of experience in designing and realizing complex systems. “Our dedication to pushing the boundaries of what is possible has made us a trusted partner for businesses looking to enhance their production capabilities,” says CEO Marijus Žaldarys of INNA.
Great diversity
The main requirement was that the end-of-line packaging system had to handle a great diversity of products and packaging. Alita sells its beverages in bottles of various shapes and volumes, which are packed in boxes and trays of different sizes. Adding to the complexity is the heavy weight, which can reach up to 280 kilograms per pallet layer. On behalf of Alita, INNA therefore sought a palletizing solution that could handle heavy weights and accommodate different packaging and stacking patterns.
The solution was found in the Highrunner HR10, the smart palletizing machine from Qimarox. What makes the Highrunner HR10 unique is the pattern generator. When the operator enters the dimensions of the packages, this tool automatically calculates the best stacking pattern. Once the operator has fine-tuned and saved this stacking pattern for future use, the machine gets to work. The incoming packages are formed into a complete pallet layer in a patented manner, which is then slid onto the pallet in one go.
Intensive collaboration
The implementation of the Highrunner HR10 at Alita was the first joint project of INNA and Qimarox. It was a very complex and challenging project, in which both parties worked closely together. “Due to the heavy weights and the diversity of products and packaging, we had to make mechanical adjustments to achieve an efficient and safe palletizing process,” says Jelle Deelman, technical product manager at Qimarox.
In addition to the Highrunner HR10, INNA also installed roller conveyors for the supply of packages and the removal of pallets. A key component is the Prorunner mk5, the vertical conveyor from Qimarox that delivers the packages to the Highrunner HR10 at the correct height. “The biggest challenge was integrating all these components. The end result is a smoothly operating system that significantly improves the operation,” says Žaldarys.
The project involved more than just the integration of transport and palletizing solutions. “In addition, INNA installed the platform, security systems, and control cabinets, and organized the acceptance tests, training, and commissioning. As Qimarox, we shared our knowledge in this area with them,” says Deelman.
More than 100 Pallets per hour
Alita now has seven Highrunner HR10 palletizing machines, the first two of which were tested and commissioned in June 2023. Before that period, the INNA team was present at Qimarox to acquire knowledge about the construction and training on the control of the palletizing machines, software operation, and machine operation. After this knowledge transfer, INNA independently installed and commissioned the remaining five palletizing machines. By early 2024, all seven lines were operational
The result is an end-of-line packaging system with a capacity of over 100 pallets per hour. The palletizing machines not only ensure efficiently stacked pallets but also use slipsheets to improve pallet stability. In addition, each pallet is automatically wrapped in foil and labeled with the correct information, barcodes, and pictograms. Thanks to the ability to log in remotely and observe with cameras, Alita is assured of continuous technical support, enhancing reliability.
High Return on Investment
With the investment in the end-of-line packaging system and the Qimarox palletizing machines, Alita’s production capacity has increased by nearly 20 percent. Additionally, by streamlining the end-of-line packaging process, the company now requires fewer personnel, leading to lower operational costs. The result is a high return on investment (ROI). Deelman: “This project illustrates the power of the collaboration between Alita, INNA, and Qimarox. By combining expertise and innovative technology, we have achieved groundbreaking success in improving the efficiency and reliability of Alita’s production lines.”
Benefits:
- Seven palletizing machines for 100 pallets per hour
- 20 percent more production capacity
- Pattern generator for efficient stacking patterns
- Extra stable pallets due to the use of slipsheets
- Automatic foil wrapper and pallet removal
- Remote support through cameras
- Fewer personnel and therefore lower operational costs
- High return on investment (ROI)
