Inalpi Installs a New DS Smith Plastics’ Bag-in-Box Filler in Italy

Inalpi, a renowned Italian dairy and key supplier of Ferrero Group (Nutella, Ferrero Rocher and Kinder brands, among others), has chosen Bag-in-Box packaging format for food industry applications due to its affordability and longer shelf life. They have partnered with industry expert DS Smith to deliver a custom designed Bag-in-Box filling system to meet its business needs.

The challenge  

Dairy companies are looking for ways to expand the business beyond retail shelves and many are finding growth opportunities in sizing their products for industrial culinary preparations and food industry use. When Inalpi, a dairy company based in Moretta, Italy experienced a demand from food companies for its milk, mascarpone cheese, cream and anhydrous milk fat they did not have a suitable 5-20L packaging to meet their needs. The new packaging had to be convenient, cost-efficient, flexible to allow quick change overs and reasonable in terms of initial capital investment.

In addition, the commercially sized packaging had to ensure preserving Inalpi’s milk quality which is a key differentiating characteristic from other competitors.  Excellent barrier properties and a hygienic filling process were required to ensure maximum food safety and product quality.

Our approach

To meet this demand, DS Smith Plastics, Rapak proposed Inalpi a complete solution consisting of Bag-in-Box packaging and filling equipment.  On top of being cost-effective and flexible, Bag-in-Box offers dairy products an extended shelf life of up to several weeks after opening.  The proposal included a custom designed Autokap™ 600 series Bag-in-Box filling system with a HEPA filter, adapted to Inalpi’s processing systems.

The Rapak Autokap™ 600 series is a single-head semi-automatic filling machine designed for a range of fresh or stable liquid products. Its advantages include very low investment cost, small footprint (3 sq m) and quick & simple bag size changes without mechanical adjustment. It is designed for both hot and cold fill of 1.5 to 20 L bags at a lower production output. Bags are manually loaded into the machine and after filling, they are released onto the roller conveyor for loading into boxes. The flow rate (BPM) is up to 300 bags/h, depending on the bag volume.

The results

Collaboration with DS Smith Plastics enabled the Italian dairy company to meet food industry needs with a new packaging format. The new cost-effective Bag-in-Box flexible packaging for fresh dairy allowed Inalpi to use chilled filling of product in combination with irradiated bags to achieve exceptional food safety standards.

About Inalpi

Inalpi is an Italian dairy supplying foodservice, retail and industrial culinary preparations sectors. Its milk powder production plant makes it unique in all Italy. It is a major supplier to Ferrero S.p.A. di Alba, the third biggest chocolate and confectionery producer in the world.

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