In the bottling of extra virgin olive oil, every stage can affect the final result. Minimising contact with air, maintaining a constant fill level, limiting downtime and ensuring the cleanliness of the containers are factors that play just as crucial a role as the quality of the raw material. It is on this basis that Frantoio Bonamini in Illasi, in the province of Verona, has integrated the Eurostar MEC AV 9/9/1VA monoblock into its bottling department – a solution that combines blow-moulding, filling and capping operations in a single machine. The company, led by Giancarlo and Sabrina Bonamini, cultivates around 25 hectares of olive groves with over 7.200 trees and produces 280.000-300.000 bottles of extra virgin olive oil annually, exporting around 20 per cent to international markets. The Illasi plant employs ten permanent staff, supplemented by seasonal workers during the harvest, and organises its operations into dedicated areas for milling, storage, bottling and visitor reception. «For all our equipment, we look for suppliers who guarantee reliable after-sales service, the availability of spare parts and assistance when needed. At the same time, we consider the machines’ user-friendliness and ease of cleaning to be essential, as they help to reduce downtime and prevent cross-contamination between one production run and the next», explains Giancarlo Bonamini.
Technology designed to protect the product
The production process at the oil mill follows a linear, highly automated workflow designed to minimise the oil’s exposure to light, heat and oxygen. After processing in the milling department, carried out using a Pieralisi/Clemente/Mori continuous-cycle system equipped with Frantoio 4.0 digital systems for temperature control, the oil is transferred to climate-controlled storage rooms, maintained at between 14 and 18 °C, where it rests in AISI 304 stainless steel tanks saturated with argon, a solution adopted to minimise oxidation. The packaging area, meanwhile, houses two different lines: a Polaris line dedicated to small batches and contract manufacturing, and another line comprising the Eurostar MEC AV 9/9/1VA monoblock, intended for both larger-scale production and premium and PDO products. The line is used frequently, as the company handles numerous brands and various packaging formats, scheduling bottling according to the best-before date to ensure customers enjoy the longest possible shelf life. «The plant’s theoretical capacity is around 2.000 bottles per hour, but we prefer to operate at an average of around 1.000 bottles per hour – notes Bonamini –. We carry out bottling operations on an almost daily basis and the flexibility of the production line is essential for managing our product range and customer-specific production runs».
From a single opportunity, a long-standing partnership
The arrival of the Eurostar machine at the company came about as a result of a particular circumstance. The monoblock had been built in 2006 for an oil mill in Puglia which, for reasons unknown to the manufacturer, never put it into operation. Eurostar and Frantoio Bonamini first came together in 2017, when the Verona-based company seized the opportunity to purchase the plant, marking the start of a partnership that has gone on to strengthen over the years. «The history of this machine is quite unique – says Alessandro Castagno, founder and CEO of Eurostar –. When we first met Mr. Bonamini, a relationship of mutual trust was established straight away. We provided all the technical support needed to adapt the monoblock to his production requirements and, over time, the professional partnership has evolved into a personal relationship based on mutual respect and shared objectives». From the customer’s perspective, too, the decision came about almost by chance. «Initially, we were only looking for a blow moulding machine – reveals Bonamini –. Instead, a dealer had this complete monoblock available, and we decided to seize the opportunity. With hindsight, I can say it was an excellent choice: integrating the blow moulding machine, filler and capper into a single machine has allowed us to make much better use of the available space within the bottling department, which was one of our main requirements».
High Vacuum: reliability and protection of EVO oil
The installed monoblock is configured with nine blow-off nozzles, nine high-vacuum filling valves and a capping head designed for applying aluminium capsules with a built-in pourer. The structure, made entirely of stainless steel, is designed to ensure durability, hygiene and operational continuity, whilst the machine’s configuration allows for rapid switching between different bottle sizes, from 250 ml up to one litre, reducing downtime during format changes.
«The filling machine’s operating principle is based on creating a high vacuum inside the bottle during the filling cycle – explains Alessandro Castagno –, ensuring the product reaches the set level regardless of minor dimensional variations in the glass containers. This technology is particularly well-suited to products of high commercial value, such as extra virgin olive oil or liqueurs, as it ensures a consistent fill level across all bottles, whilst also enhancing the appearance of the packaging. Furthermore, the system reduces liquid turbulence, minimises foam formation and the incorporation of air, helping to preserve the product’s organoleptic characteristics». From an operational point of view, the machine has also proved well-suited to the mill’s organisational needs. «It could easily handle 2.500 bottles an hour, even for production runs dedicated to a single bottle size and a single product», comments Bonamini.
«We run it at lower speeds because our production is very diverse, but we appreciate its reliability, the reduced need for unscheduled maintenance and the ability to use it intensively. Another important aspect – continues Bonamini – concerns IFS certification: Eurostar has fitted a pressure gauge that constantly monitors the blowing pressure to ensure it remains stable at 5 atmospheres, with a system that automatically shuts down the machine should this parameter not be met».
