Levissima

Top productivity and a sustainable footprint to protect the brand

Launched in March 2018, Levissima’s new corporate identity is brought to life in the re-designed bottle and label of the leading Italian water brand. The pure and light mineral water has its origins in an extraordinary natural environment, coming from the ancient glaciers in the heart of the Alps. The top of the Alps are present on Levissima’s new logo and label[4], which is now designed on transparent film. The colour of the logo is reflected on the new green cap, shaped ergonomically and therefore easy to open for consumers. 

To tackle Levissima’s specific challenges connected to the new bottle and label, Sidel installed an EvoDECO Roll-Fed labeller with two stations, running on every other bottle, handling lightweight containers and ultra-thin labels. The ergonomics of the entire solution have been optimised for performance and efficiency, with all main components fully visible and accessible during production. With no need to disengage the station, this open design is particularly beneficial during changeover and maintenance. The label application on Levissima’s new squared bottles ensures a very stable and accurate process at high speeds, thus addressing the two most important points for the water producer: excellent quality and high reliability. 

The new labeller is equipped with unique features leading to improved uptime: the cleaning of the EvoDECO Roll-Fed is performed automatically during production by a system installed on the vacuum drum, which is built in lightweight sectors for easy changeover and maintenance operations. This system removes any glue residuals for an overall higher performance. The labeller also comes with an automatic label extraction system, protected by a Sidel patent, ensuring that no downtime occurs due to a missing bottle or labels not being properly applied on the bottles, thus supporting a smooth and consistent flow of production. With the new, patented vertical melter and the laser engraved glue roller, glue is melted on demand and circulated at a precise temperature. This reduces glue consumption for better overall quality and improved sustainability. 

Combining food safety with high performance 

As Levissima wanted to significantly increase performance and production capacity, with no compromises on food safety, the Sidel Matrix™ Combi came as the natural choice. Integrating blow moulding, filling and capping processes into a single system, the Combi reduces operating costs and uses up to 30% less floor space compared with traditional standalone equipment. Using fewer component machines, the solution offers up to 4% higher efficiency levels than standalone machines, on top of lower energy consumption and faster format changeovers. This results in a reduction of operating costs by up to 12%, saving labour, raw materials and spare parts. 

The Combi supplied to the Cepina site is equipped with a Sidel SF100 no contact filler, ensuring optimum uptime and the highest productivity. The reduced filler enclosure allows for utmost hygiene, while minimising use of water and chemicals during the external cleaning process. This is how the solution achieves full food safety – a highly important factor for Nestlé Waters. 

Contributing to energy savings and optimised uptime 

The Sidel Matrix Combi at Levissima’s site also features OptiFeed® – a cap feeder that is based on a patented waterfall technology, combining elevation, orientation and high-speed feeding with energy savings. The latter is achieved due to the individual cap-elevating system that eliminates the need for compressed air during cap extraction for better quality caps and reduced environmental footprint. With ease of operations and maintenance at its core – due to the reduced height, easier accessibility and durable materials – OptiFeed also features an integrated inspection system, ensuring 100% caps quality. 

The highly flexible EIT® (Efficiency Improvement Tool) is also part of the solutions Sidel supplied to the leading Italian water brand. Automatically recording 24/7 raw production data, EIT calculates a wide array of KPIs to help measure performance, analyse production issues, detect efficiency loss sources, and perform root cause analyses. It is designed to ultimately decrease unplanned downtime, reduce waste and costs, and increase Levissima’s output. By giving employees at all levels of the organisation real-time access to relevant and actionable information on production-related issues, it makes sure that the quality of the water as well as the line capacity stays on the desired level.