Turnkey filling lines — one supplier from the empty container to the wrapped pallet
A filling machine is only part of a line. Containers have to arrive, be opened, filled, closed, sealed, labelled, coded, palletized and wrapped, often in a hazardous area or a clean room, and every step depends on the one before. In a turnkey project, AiCROV engineers the whole line, builds the filling machines, integrates the rest of the equipment, tests everything together in Tarragona and installs it at your plant. You have one supplier and one technical contact for the whole line.
What a turnkey line can include
Run with our Project Execution Process (PEP)
Like every AiCROV project, from a single machine to a complete line, turnkey lines are run with our own method, the PEP: one project manager, a gate at every stage, an internal test (IFAT) before the FAT with you, a site readiness check before installation and a punch list that follows every open point until it is closed. In a turnkey line this matters even more, because more machines and more suppliers mean more interfaces to manage.
Designed as one line
Before anything is built, we lay out the whole line on your floor plan: where pallets arrive, where operators and forklifts move, how containers flow between machines and where they wait. This is one of the layouts our engineers have designed.
Turnkey lines we have delivered
Complete lines and plants supplied by AiCROV, from empty container to finished pallet.
Turnkey packaging plant for crop protection — four EL2-E-V jerrycan lines and one robot palletizer, Nutrien, Melbourne, Australia
For a new crop-protection factory in Melbourne, Nutrien wanted a single supplier and one technical contact for the whole packaging plant.
EL2-E-V Filling, Capping and Labelling Line for Acids and Bases — Kersia, Poland
Kersia needed, at its plant in Poland, to fill, cap and label aggressive acids and bases in five canister sizes on one line.
EL2-B-6 automatic drum filling and complete end of line for lubricant oil — Tyumen, Siberia, Russia
A lubricant oil producer in Siberia needed a drum line that went from the empty drum to a finished pallet, wrapped and labelled.
Turnkey GMP filling plant for lactic acid — jerrycans, drums and IBCs in one clean room, Barcelona area, Spain
A lactic acid producer for the food and pharmaceutical industries needed to fill 25-litre jerrycans, 200-litre drums and IBCs inside one GMP clean room.
EL2-B-4 drum filling line with automatic palletizer for lubricant oil — Indian Oil (IOCL), India
For a second line, Indian Oil wanted drums uncapped, filled, recapped, sealed and palletized automatically, with no operator handling the product.
Four Explosion Proof Robot Filler Lines for Flammable Petrochemicals — BPCL, Kochi, India
BPCL needed very high output of highly flammable propylene derivatives, in a plant where the whole filling area is a hazardous zone.
Turnkey EL2-E line with robot palletizer for adhesives in 30 L metal drums — Dynea, Norway
Dynea, a specialist in wood adhesives, needed to fill a wide range of resins and adhesives into 30-litre metal drums at high output.
Explosion Proof SP3 Line for Polyols — Decap, Fill and Recap Drums and IBCs for Croda Ibérica, Spain
Croda needed to fill polyols into drums and IBCs in a hazardous area, and wanted to keep forklifts out of the production hall.
Why one supplier for the whole line
Frequently Asked Questions
Can a turnkey line include machines from other manufacturers?
Yes. We build the filling machines and integrate third-party labellers, coders, wrappers and other equipment, under one control system and one responsibility.
Can you connect a new line to equipment we already have?
Yes. For example, a Robot Filler line in Belgium was connected to the customer’s existing chain conveyor and stretch wrapper.
Who installs the line?
Our technicians install and commission it and train your operators. The Site Acceptance Test (SAT) is done with you at your plant.
How do we know the line works before it arrives?
The whole line is assembled and tested in our workshop in Tarragona: first in an internal test (IFAT), then in the Factory Acceptance Test (FAT), in which you take part, before shipment.
Can the whole line be built for hazardous areas?
Yes. Fillers, conveyors and the rest of the line can be built in an explosion proof version, with nitrogen inerting and grounding checks where the product requires them.
Can a turnkey line grow later?
Yes. Many of our machines are designed with free stations or space for more filling heads, so capacity or functions such as capping can be added on the same line.
Do you support the line after installation?
Yes: remote assistance, spare parts and maintenance plans for the whole line.
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