How Chiarli customizes Lambrusco wine

For more than a century and a half, the Italian wine producer ‘Chiarli 1860’ has renewed its production processes in order to ensure high quality typical wines. The last intervention that took place on the production lines also provides for two modular labelling machines, for which chiarli has continued to rely on the expertise of P.E. LABELLERS.

Chiarli 1860’ is one of the oldest wineries in Emilia-Romagna and a well-known brand, in Italy as well as in many foreign markets, for the production of Lambrusco and regional wines.

12 bicchiereSince 1959 wines have been prepared and fermented through Charmat method, then bottled and packed with modern production facilities thanks to two dedicated lines, one of 18,000 and the other one of 10-12,000 bottles per hour. The bottles used by Chiarli – ‘emiliana’, ‘renana’, and ‘mirage’ – are received in the glass fleet outside the manufacturing plants. Here the glass containers are stored for a short time before starting their journey into the heart of this factory situated in the province of Modena.

Everything starts when the bottles are collected by an operator, compacted again into pallets, and transported on the pallet transfer unit within the plant. The machine breaks up the bench and directs the containers on the conveyor belt. The subsequent steps are managed by a series of specific machinery that provide, in order, to rinse and wash the glasses with sterilized water, filter the wine ready for bottling through a microfiltration process, fill the bottles, seal them, and implement the pasteurization process. This cycle lasts an hour and a quarter. With the pasteurization process, approximately 10,000 containers enter the specific machine at a temperature of 2-3°C, gradually and in different steps they are brought at a temperature of 54°C for about 25 minutes, and cooled to 28-30°C. At this point they exit from the pasteurizer. Then the containers pass in a dryer – a machine provided with multiple fans that blow warm air in order to remove any residual water drops remaining on the glass after the pasteurisation process – then in the shrink capsule application machine, which has the task of placing the heat-shrinkable or pneumatic capsule on the bottle, and finally in the labelling machine. This step is crucial in order to ‘dress’ and characterize at its best, according to both standards of the company and customers’ requirement, each bottled product.

Targeted investments

Once labelled, the production lot is affixed to the bottles by a marker. Through a divider, then, they are distributed in multiple lines and placed in boxes. Next to the divider, on the line, the packing machine is placed. This tool has the task of positioning the containers, completed and ready for consumption, in suitable cartons previously formed, labelled, and marked. The cartons, are then weighed on a machine which checks that the content of each one is in compliance, then they are closed, by means of automatic sticking, and transported to the palletizer. This machinery is responsible for the creation of pallets. Finally, before being moved in the warehouse, waiting for shipment, the cartons are made safe with stretch film, applied through the use of a wrapping robot.

As for this tool, through which 18,000 bottles per hour, both 1.5 l and 0.75 l, are produced, numerous investments have been performed. They involve, among other things, dryer, capper, divider, a part of the conveyor belts and, especially, the labeller. For the plant which processes 10-12,000 bottles per hour, too, which concerns different sizes for 0.75 l and 0.375 litre containers, an important renewal has been projected. It concerns the labeller as well as all the machines that carry out the process of bottling, from the exit from the pasteurizer to packaging.

Flexible and resistant labelling machines

Anselmo Chiarli, Managing Director and CEO of Chiarli, specifies: «All the investments we have made in recent times have been implemented in order to enhance and upgrade our wines ant their image. This way, we want to guarantee to our production both quality standards and organoleptic characteristics that reflect the true nature of Lambrusco, as our tradition reminds us.  We aim at helping to change the perception of Lambrusco in the markets and, above all, among our consumers. In order to reach this aim, in addition to expanding our production capacity, in order to increase fermentation time for some days and, therefore, enhance both finesse and elegance of our wines, we decided to invest to improve our lines of bottling and packaging. Without a doubt, two machines have been fundamental in this sense: capping and labelling machines. The latter ones, in particular, resulted to be extremely flexible, modular and solid, an ideal mix that gave us the opportunity to do what we aimed for: customizing at our best the orders for each customer».

Modular Top 1120

For its labelling machines, Chiarli has decided once more to trust the experience of P.E. LABELLERS. The two machines, both Modular Top 1120 model, are equipped with system of plate rotation with electronic cam and removable labelling modules on trolley, for four positions on each labelling machine. This system is able to meet the most various needs in terms of gluing and self-adhesive applications, in a non-stop configuration. In addition, both machines are equipped with a station for the application of ‘L’ and ‘U’ seal, for a total of 10 different bottle sizes with 25 different types of labels.

13 etichettatrice (11)Emanuele Rubbiani, who is in charge of bottling processes for Chiarli, says: «These models provide the opportunity of implementing, even on the same bottle, collar, label, stamp, two self-adhesive labels, and glued back label. In addition, the self-adhesive group can also be applied instead of a group with glue, for example, because the groups are interchangeable. This factor guarantees extreme versatility. The choice of P. E. LABELLERS has been difficult, because before deciding we evaluated several proposals, also characterized by lower prices. At the end, however, we chose to rely again on the expertise of this Company in Mantua, which has been our supplier for many years. The policy adopted by Chiarli does not consist in ‘using’ our suppliers, but growing with them, and since we have always been satisfied by P.E. LABELLERS and have established a very good cooperation, we renewed our trust to them».13 etichettatrice (16) stabilimento 10mila b-h

Understanding customers and machines improving
Over 40 years of activity, 8 production plants located in the province of Mantua and seven sales offices around the world, 36,000 square metres of total surface area occupied by factories, and more than 400 labelling machines produced per year: these are the numbers of P.E. LABELLERS, located at Porto Mantovano in the province of Mantua, a leading manufacturer in the domain of automatic labelling machines. Since 2000, the strategy adopted by P.E. LABELLERS has been characterized by its direct presence in global strategic markets: China, Africa, Brazil, and, by 2015, Southeast Asia, too. We asked Luca Carollo, Sales Director and Key Account Sales at P.E. LABELLERS, about the values ​​at the base of the activity carried out by the Group. «The market of industrial high added value machines has greatly evolved over the last 10-15 years: customers no longer require only a well-performing machine, but they want to take advantage of security in terms of both services and on-site assistance. With our presence, we can meet this requirement, because we believe that the most important value is to understand our customers, offer what they require, and improve the product depending on the dynamics in the different markets. The average of 10 worldwide patents every three years and the creation of one P.E. LABELLERS agency per year, as it happened in Algeria in 2014 and in Malaysia in 2015, are the actual proofs of our intentions. Regarding Chiarli, it needed a solution that could meet the demand of growth of its production combined with a request concerning application of self-adhesive labels. Our machines have been the ideal solution, because they can offer huge potential: they were born for the application of self-adhesive labels, but, thanks to P.E. LABELLERS machines modular standard structure, from the smallest to the largest, they can be modified for the cold glue application of adhesive labels. In addition, they can be integrated with possible optical orientations managed by servomotors with integrated drive. I think that both confirmation of the faithfulness of Chiarli to our company and supply of these two important machines are just the first step in the path of trust and satisfaction that we will commit to pay back to this customer in the coming years of partnership».
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