Yalumba APB Loader

When Yalumba needed to automate tirage bin loading, no existing solution was available. Foodmach agreed to develop one for a fixed price.

Background

Yalumba called Foodmach in to assess a bottle-handling challenge in its traditional-method sparkling wine production.

Loading bottles into timber tirage bins was a manual process with precise requirements. Bottles needed to move from upright to horizontal, form an interlocking pattern and be placed in complete layers for secondary fermentation and storage.

Foodmach assessed the application and found no existing solution available to meet the requirement. The teams agreed on a fixed price for Foodmach to develop a new one, giving Yalumba cost certainty for the agreed scope.

The resulting Automatic Pallet Bin (APB) Loader was designed and manufactured at Foodmach’s Echuca facility, with a design capacity of up to 5,500 bottles per hour.

It has successfully completed Factory Acceptance Testing (FAT), with site installation and commissioning to follow.

A handling challenge that called for new engineering

Automating the process meant controlling every bottle through a sequence of movements while maintaining the required packing pattern.

The system needed to count and group incoming bottles, turn them horizontally and nest them into stable rows. It then had to place each complete layer inside a timber bin at the correct height, repeating the sequence until the bin was full.

Protecting bottle integrity throughout the process was essential. The loader also needed to integrate with Yalumba’s existing tirage line and provide controlled access for operation and maintenance.

Key objectives for the project were:

• Improved ergonomics: reducing the physical demands of repetitive bottle handling.
  
  
• Reduced manual-handling risk: automating the loading of bottles into timber tirage bins.
  
  
• Higher throughput: developing a system designed to handle up to 5,500 bottles per hour.

From production problem to purpose-built machine

Foodmach brought its mechanical engineering, manufacturing and controls teams together to develop a coordinated loading system.

Forming the bottle layers

Bottles arrive upright from the production line, divide into two lanes and accumulate into programmed groups. A controlled orientation mechanism turns them horizontally before the staging system positions and nests them into interlocking rows.

Three rows combine to form each complete layer.

Loading the timber bins

A transfer mechanism places the completed layer into the bin at the required height and position. Loading continues automatically until the programmed layer count is reached, then the system signals for a bin change.

Managing the complete sequence

Foodmach developed the electrical and software package alongside the mechanical system. Operators use a central HMI for recipe selection and machine operation, with diagnostics and alarms to support fault finding.

Perimeter guarding and monitored access points are integrated with the machine’s safety controls.

Factory-tested before it reaches the production floor

The complete system was assembled and factory-tested at Echuca, bringing the bottle-handling mechanisms and control sequence together before site installation.

For a newly developed machine, this is a critical step in Foodmach’s Vertical Startup System towards production readiness. It provides an opportunity to assess the integrated system before it reaches the customer’s line and supports a more controlled installation and commissioning process.

The loader has successfully completed FAT. Sustained production performance will be confirmed following commissioning at Yalumba.

Engineering ownership, with an agreed price

Yalumba brought Foodmach a problem without an available solution. Foodmach committed to developing the equipment to solve it, at an agreed fixed price.

With design, manufacturing and controls delivered in-house, Foodmach carries responsibility for the complete system through to installation and commissioning.

Yalumba has one engineering partner accountable for turning the production requirement into working equipment.

Customer: Yalumba Wines

Application: Heavy wine and sparking wine bottle handling and timber-bin loading

Solution: Newly developed Foodmach Automatic Pallet Bin Loader

Commercial approach:  Development for an agreed fixed price

Design capacity: Up to 5,500 bottles per hour

https://foodmach.com.au/make-a-timeScope: Design, manufacture, electrical and software, FAT, installation and commissioning

Project status: FAT completed; site installation and commissioning to follow

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