XTS technology from Beckhoff enables cycle rates up to three times faster.
Tetra Pak has received the Premio Innovazione for its Cap Applicator 40 Speed Hyper, a machine that significantly advances the performance limits of conventional packaging lines.
The award recognises a fundamental rethink of the drive concept behind high-speed cap application. Instead of relying on a traditional mechanical drive train, the system uses a highly dynamic mechatronic solution based on Beckhoff’s XTS linear transport technology. The result is a three- to four-fold increase in performance compared to conventional systems.
At the core of the solution are two parallel XTS tracks, each 4.5 metres long and equipped with 55 individually controllable permanent-magnet movers. These freely programmable carriages allow each cap to be positioned and applied independently, in real time, with accuracy down to one-tenth of a millimetre. This level of control enables the system to compensate reliably for natural variations in cardboard packaging.
By replacing mechanical components with software-defined motion control, XTS increases digitalisation and data transparency within the machine. It enables condition monitoring, supports quality assurance, and improves overall system availability. Communication is handled via EtherCAT, with configuration and control managed through TwinCAT, allowing seamless integration with the rest of the machine’s automation and drive systems.
From a production and plant design perspective, the impact is substantial. A single XTS-based line can replace up to three conventional capping systems, reducing floor space requirements and lowering construction costs. At the same time, reliability and uptime are improved, while product changes and format conversions are largely handled through software rather than mechanical modification.
The Premio Innovazione was presented at the SMAU innovation forum in Italy. The award is based on user nominations and highlights solutions that demonstrate clear practical value in real-world industrial environments. The fact that the Cap Applicator 40 Speed Hyper is already deployed by major global food and beverage producers underlines both its maturity and its potential as a platform for further automation and digitalisation.
