Industrial research is the heart of our business. It is not simply about improving a technical feature or reducing maintenance times, it's about re-thinking processes, transferring solutions applied in other sectors, finding new ways to anticipate customer needs. It means going away from the beaten path and looking ahead.
Following is a brief summary of some of the main innovations generated by Coesia companies in the different sectors we operate in:
In tobacco making and packing, G.D created milestones in the industry by radically changing existing packaging processes. In the early Sixties, G.D launched a revolutionary wrapping machine, the 4350/Pack, becoming the outright leader in the sector. Soon after, the X1 and X2 packers were a breakthrough, producing three times as many packets compared to the existing machines. In the Nineties, G.D created the first double-rod maker allowing to double the production speed available on the market and at the same time to treat the product more delicately. In the 2000s another radical innovation: G.D launched the first continuous motion packer with a speed of 1000 packets a minute and a more delicate handling of the product.
In the sanitary napkins sector, in 2001 GDM patented a modular process line for the manufacture of absorbent disposable articles; in 2005 the company invented an upper and lower tissue core forming solution for single and double fluff core for baby and adult diapers; also in 2005 the rotary folding welding wheels to transform a traditional open baby diaper in a pull-up product was created; another patent in 2007 covered the pick and place solution to apply rear elastic ears on baby and adult products;
In the confectionery, chemicals and liquids sector, Acma has patented more than 600 innovative solutions and 200 different packaging forms, materials and designs. Just a few examples in recent years: in 1993, Acma created a candy and chocolate wrapping machine offering the highest speed on the market (1000 ppm); in 2000 the Virtual Level System for the pressurization of the liquid level inside the tanks to manage complex high viscosity products; in 2001 a direct link belt between the soap stamper system and the wrapping machine to reach a speed of 500 soaps/minute; in 2005 the innovative "ZipTop" carton for candies, chocolates and pharmaceuticals, with hermetic closing features; in 2008, the WM net weight filler for innovative solutions in container handling and in 2010 a new candy and chocolate wrapper capable of integrating the alternate motion of the feeder with the continuous motion of the wrap.
In flexible packaging systems: the new aseptic horizontal form-fill-seal machine for flexible pouches patented in 2005 by Volpak opens the stand-up pouch package to the dairy and beverage industries; the new patented cap closure, specifically designed to be sealed on flexible pouches, guarantees seal integrity, high machine performance and an untouchable pouch finish; the Brickpouch, a new package patented in 2010, combines the advantages of flexible pouches with those of semi-rigid bottles
In online printing systems: Hapa created the first flexographic aluminium foil printer; the first UV Flexo printer for foils, leaflets, carton and lidding materials; the first print mat engraving system; the first fully-digital Drop-On-Demand (DOD) inkjet system for the Late Stage Customization of foils, cartons,leaflets, labels, and web materials
In visual quality control systems, Laetus developed a completely new web technology system to allow different solutions and products to be combined and navigated from one panel and in 2011 the 3D system for blister check also in difficult situations without using laser technology.
In tube filling, Norden created some innovations which changed the industry, such as: in 1983, a hot air sealing system providing a precise control of the sealing temperature so as to allowing tube print decoration in the sealing area. In 1992, Norden introduced the Design-a Seal®, a refinement of this welding method for sealing tubes of varying shapes.with an attractive finish. In 1985, the company launched the Multicolour filling, the possibility to fill a 3-colour product based on having one pump for each colour at a high speed (up to 500 tubes a minute). In 1997, the robot tube loader was created – a flexible infeed system that picks the tubes directly from the tube box and places them into the tube holders. More recent innovations are the Automatic Depalletizer, a robot system that picks the tube boxes directly from the pallet and allows them to be recycled; the Compact Case Packer, is a servo-driven pick-and-place robot that automatically packs shipper boxes in a compact and cost-effective way; In-Line Leak Detection, is a technology that detects leaks by sensing the concentration of a tracer gas in full speed production with complete quality control; Scoop Seal®, a unique package on the tube market with an ergonomic design providing a perfect grip to squeeze all of the product out of the tube. Its compact design allows more space in each tube tray and pallet, maximizing storage capacity.
In the lipstick filling sector, in 1994 Citus-Kalix patented the hotfilling of lipsticks in soft moulds, a process enabling the manufacturing of lipsticks with various shapes and with a logo impressed on them.
In 2010 the CRL09 high speed lipstick machine was launched (100 p/mn).
In 2011, the company developed a new range of tube filling machines: the KX3T. With the same frame, simply by adding options the customer can upgrade the machine from 50 to 80 pcs/mn.
In feeding and depalletizing systems, ADMV has registered patents for standard feeders (blade elevators) using gravity to select the products and for a depalletizer.
In the production logistics sector, FlexLink is the inventor of modern conveyor systems. The change from previous technologies lies in the standardization and modular design of high quality components. More than 10 years ago, software was added to the production logistics offer to provide solutions with high process efficiency, to the benefit of the user.
In 2010, FlexLink launched a state of the art product range of conveyors for the health care industries, based on a compact conveyor platform, with high efficiency drive technology and embedded controls. In 2011, the new generation of innovative-design stainless conveyors was launched.
Which were the winning factors in this successful story? Innovation is not generated by an individual alone. It is the result of a series of favourable conditions, which in our case consisted in a creative company culture, the commitment to invest in Research & Development, the presence of a mechanical district offering a network of opportunities, such as the transfer of technological know-how and the availability of outstanding talents. All these factors, combined with an increasing market demand for higher production volumes, were the trigger for the creation of new technologies and state-of-the-art solutions.