RG270: An Advanced Filler, in many Ways

Following is a general overview of the RG270’s main features. This packaging machine is ideal for medium and large manufacturers with a yearly production ranging from 15 to 25 million packages.

Let's start by saying that Galdi manufactured this filler WITH its customers.

Before embarking on the project, we asked owners of previous Galdi models to provide feedback based on their direct experience.

Our efforts were rewarded, as top companies in several countries installed our RG270, including:

• Cumberland Dairy, United States: ESL and fresh milk >>> Click to find out more
• P.T. Greenfields, Indonesia: ultra-pasteurized milk >>> Click to find out more
• Proan, Mexico: egg white, whole egg >>> Click to find out more
• JSC Kirovskiy Dairy, Russia: milk, kefir, yogurt drinks, fermented baked milk, sour cream >>> Click to find out more

• Up to 7,000 cartons/hour
• Formats: from 250 to 2000 ml
• Sizes: 57x57, 70x70, 70x95, 91x91, 95x95mm
• Filling accuracy (liquid products): +/- 1 gram;
• Handles all viscous, liquid, foamy products, or pieces up to 10 mm.

• Fresh (milk, up to 7 days)
• Clean (dairy products up to 10 days and fermented products up to 30 days)
• Ultra Clean (ESL up to 28 days, liquid egg up to 60 days)
• Warm Fill (wine and high-acid products, up to 12-month shelf life)
• Hot Fill (juice and acid products, can be stored for up to 12 months)

Cap applicator can be added as optional (if ordered, it can be deactivated according to recipe selected from panel).
Carton seal cooling (bottom and top) using iced water to ensure maximum precision.

Discover the new 3-A compliant, 2-liter/Half Gallon RG270 packaging machine:

Our RG270 was a real watershed in Galdi’s design philosophy.

Before this model, our machines greatly differed from one another as far as technical features, frame and design “style” are concerned.

The concept of platform, meaning the creation of a basic project on which to develop bespoke configurations for specific products and packaging solutions, was first introduced with the RG270.

Thanks to this new approach, our troubleshooting and continuous improvement capabilities have increased significantly.

The RG270 was the first model designed according to Integrated Design principles, requiring:

• specific configurations, depending on product and closure types
• purpose-built stations
• modular stations to enable simpler upgrades
• focus on synergy between components

Food safety is one of Galdi’s priorities.

Our RG270 was designed to be advanced in terms of hygiene standards too, in compliance with FCM regulations laid down in both EU and US legislation (3A UL, FDA).

Galdi’s design teams developed several solutions to reduce contamination risks in packaged products both inside and outside the machine, a particularly important factor for ESL products and liquid egg.

Implemented solutions include:

• clean room overpressure
• sterile air flow in filling areas and on dosing tanks
• automatic cleaning of CIP boxes
• automated SIP and CIP cycles
• HEPA filter hoods

A special emphasis was placed on cleaning and sanitation cycles. The design refinements we came up with ensure a more accurate cleaning – also for parts not in direct contact with the product – and remove the need for manual intervention. Nonetheless, cleaning cycles were kept as short as possible (1 hr 30 min).

This progress too is the result of in-depth and ongoing research based on the principles of Hygienic Design.

We can also provide direct support to address any hygiene concerns you may have, with a range of specific trainings and now also with our new post-commissioning cleaning & ATP test service.

We’ve already discussed the concept of “robustness” in previous articles. By robust, we mean a machine that ensures the same performance over time, regardless of site productions specifics, carton format or type.

This last point is particularly important, as the RG270 is designed to handle:

• any product type (liquid, viscous, foamy), pieces up to 10 mm in size
• any Gable top design and format
• any carton type

This advancement was possible thanks to our long-standing cooperation with the world’s main manufacturers of multi-layer carton packaging materials and the numerous tests we conducted together.

The filler can leave the factory with multiple native configurations and further upgrades are possible at a later stage.

In the event of a paper type change, the machine requires only minimal adaptations in relevant stations. This is really useful, considering the introduction of reduced weight, greener packaging solutions.

Of course, we didn’t achieve this result overnight. Numerous tests and analyses were needed to get to this point. The collaboration with the Mechanical Engineering department of the University of Padua proved very valuable to investigate the physical-mechanical characteristics of multi-layer cartons and to optimise welding and folding processes.

With the development of the RG270, we looked at the issues of consumption reduction and environmental sustainability from a scientific point of view.

In cooperation with the University of Padua, we conducted a study on the impact of our filling machines in terms of CO2 emissions and water consumption all through the machine life cycle.

We also took a closer look at the fillers’ consumption levels, with a focus on reducing energy waste and component wear.

In line with the philosophy of Eco Design, our RG270 features several solutions regarding for instance the cap applicator, doser and welding system.

Their see-through design has become a hallmark of Galdi’s filling machines: the large windowed area enables you to have a better view and control over the filling process.

Another distinctive trait, albeit less manifest, is the accessibility to work and maintenance areas.

All the areas surrounding mechanicals parts, and also around the mandrel carousel, are designed to ensure easy and safe access.

It was also thanks to some of our customers that we achieved this result, as they let us conduct an accurate analysis of the use and maintenance of their filling machines.

In designing the RG270, the logic was clear, as we set out to achieve:

• maximum machine accessibility for routine operations for operators, or else such operations had to be automated
• accessibility and comfort for maintenance staff, making the disassembly of components as straightforward as possible

Designing and developing machines according to the principles of Ergonomic Design (focused on machine operators) and Design for Maintenance (paying special attention to maintenance staff) is paramount for Galdi. Efforts in this direction have led to progress and improvements over the years.

Our RG270 filler is also advanced in terms of usability or, shall we say, simplicity.

The panel interface running on a PC-based platform has been “revamped” to provide only useful and clear information, both for operators and maintenance technicians. And our dedicated Machine Intelligence team keeps developing new solutions.

As for diagnostics and assistance, in addition to panel functionalities, maintenance staff can also rely on a number of helpful tools: MASH, our advanced monitoring system, our remote video assistance service that uses augmented reality, as well as the Teleservice sharing system.

Thanks to these tools, we can guarantee more precise and accurate Planned Maintenance Plans, resulting in considerable savings over time.

Considering how each food pack “weighs” on the OEE of a manufacturing facility, the RG270 was conceived to ensure top performance levels and maximum reliability.

Also, with a view to continuous improvement, we integrate design research and optimization with a team dedicated to claim resolution in order to detect anomalies and unexpected behaviours.