Smart Motion, Fast Production: How XTS Transforms Pharmaceutical Bottling Lines
- Jeff Johnson
- Sep 25
- 5 min read
Intelligent transport system enables flexible bottle handling in pharmaceutical production
A longtime user of EtherCAT and PC-based control, Italian packaging machine manufacturer Marchesini Group has now adopted Beckhoff’s XTS linear transport system for filling lines used in the pharmaceutical industry. In a monoblock machine for filling and capping bottles, XTS makes transport more flexible while reducing setup times and energy requirements.
Since its founding in 1974, Marchesini Group has always paid particular attention to the key components of its systems, including the machine software. “Unlike system integrators, our hallmark is that we are an all-round manufacturer: We develop all of our machine technology in-house and know it inside out,” explains Stefano Gualmini, head of Automation R&D at Marchesini. Keeping with this attention to detail, Marchesini’s long partnership with Beckhoff, dating back to the 1990s, is based on a precise shared vision with a solid foundation.
From proprietary to open, PC-based control architecture
“Since the early 1990s, we have focused our area of interest on standardized and open platforms. We wanted to move away from PLC-based control architectures,” recalls Gualmini. “This was primarily due to the availability and reliability of PC hardware and its excellent price/performance ratio.” This mindset also led the company to become an early adopter of EtherCAT, implementing the technology in 2007, not long after it hit the market. “We consider EtherCAT the backbone of our automation processes in every respect,” states Gualmini. He points out that the company’s selection criteria were – and still are – based on the platform’s open architecture, efficiency, and ease of implementation. Marchesini has also been using EtherCAT to capitalize on the potential of functional safety via FSoE since 2013. Integrating safety functions on the same bus system has reduced wiring work by around 50%. Taking this approach also optimizes the communication between the safety and standard components.
Another core area of expertise for suppliers of packaging and filling machines is motion control. After an intensive benchmarking exercise between 2018 and 2019, Marchesini once again decided that Beckhoff was the right choice. “We knew that we would have to take a quantum leap in terms of motion control and mechatronics to prepare for the challenges we would face in the coming years,” notes Gualmini. But the Marchesini Group didn’t just choose Beckhoff as a partner for motion applications because of their previous partnership. Rather, the company was impressed by the quality and diversity of the available technologies. Although initially classic rotary motion components were used, the XTS linear transport system now also serves as a mechatronic drive solution, appearing in the Compact-24 monoblock machine, designed for counting solid products (tablets, capsules, pills, etc.) and adding them to bottles.
Using XTS to streamline processes
At first glance, the Compact-24 is a typical example of a linear machine. At the infeed, a mechanical system takes the medication bottles from a stack and places them individually on an XTS mover. The movers then travel to the filling station, where hoppers appropriate for the task fill multiple bottles simultaneously with pills that have already been counted. The bottles are then transported to the next station, where they are transferred to the rotating capping unit. After that, XTS is used to move everything back to the unloading station, from which point the containers are sent on for further processing after a series of checks.
Where the Compact-24 breaks the mold is through its use of XTS for dynamic bottle transport. Each mover moves autonomously and is positioned or grouped according to the desired work sequence. With this technology, Marchesini machines now boast high linear speeds that minimize the times required for returning the empty movers to the pick-up station and for changing bottles. XTS also makes it easier to convert the product format. Using the control panel, the movers can be positioned in groups and moved to defined locations for exchanging product-specific adapters.
The Compact-24 offers two special features. Firstly, the in-and-out movements of the bottles can be synchronized at variable intervals. Furthermore, the software enables the movers to be configured and adapted to the new containers and their properties, such as shape, storage capacity, and distance between products, when the product is changed. “XTS enables us to provide flexible and consistently optimized transport,” enthuses Gualmini.
Adding pills or tablets to bottles is not as simple as it may seem. These products tend to fall from the feed system hoppers into the bottles at different speeds. Additionally, the filling time for each individual bottle is affected by a visual integrity check, and multiple bottles are always filled in parallel. That is why each bottle must be handled individually. Compared to conventional mechanical solutions, XTS can fully harness its strengths with the individually controllable movers in the Compact-24. The XTS technology enables each bottle to be handled individually, an unbeatable advantage when it comes to efficiency. “Given that the filling station has to count the tablets for each bottle, XTS was the ideal solution for our synchronization problems,” explains Gualmini.
In mechanical terms, the XTS motor modules and guide rails are fully integrated into the machine frame. From a software perspective, the movers are integrated into the automation project like normal drive axes. Several dozen axes may be involved, depending on the design, without affecting the application. “This offers considerable advantages in terms of flexibility and speed compared to conventional motion solutions,” emphasizes Gualmini.
Machine cycles increased by 25%
Marchesini has been able to achieve significant, measurable improvements. By integrating XTS into its machines, the machine builder has improved accuracy with respect to tracking errors in certain applications by up to two orders of magnitude. This has helped increase the Compact-24 production speed from 120 to 150 bottles per minute. And using the AX8000 multi-axis servo system with its intermediate voltage circuit (DC bus) has resulted in significant energy savings of up to 20%.
“Beckhoff provides us with a constant incentive to exploit the potential that new technologies can bring in terms of efficiency and innovation. For that reason, I’m positive that our long-standing partnership will be even closer in the future,” concludes Gualmini.
By integrating Beckhoff’s XTS into the Compact-24 machine, Marchesini Group has achieved faster changeovers, greater flexibility, and significant energy savings while still increasing output. With individually controllable movers ensuring precise bottle handling and streamlined processes, the company is well-positioned to meet the pharmaceutical industry’s evolving demands for years to come with the support of Beckhoff technology.
Ready to see how XTS can revolutionize your pharmaceutical applications? Connect with your local Beckhoff sales engineer to get started today.
Jeff Johnson is the Mechatronics Product Manager at Beckhoff Automation LLC
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