‘Magic’ machine uses linear transport to cap 25,000 cartons an hour
11 August 2025 
A pilot carton-capping machine installed at a plant in Italy can fit 25,000 caps every hour – almost three times as many as conventional capping machines. Dubbed the “magic machine” by the customer, it achieves its performance using a combination of a linear transport system and PC-based control.
In the food and beverage industry, packaging machines must meet ever-tougher demands for speed, flexibility and efficiency.
Tetra Pak is a leading food processing and packaging provider, headquartered in Sweden. Its customers have the expectation that it will deliver higher production volumes using machines that take up less space, use less energy, and reduce operational downtime.
Traditionally, applying caps to portion-sized beverage cartons has been a mechanical process limited by inflexible hardware and physical cams. According to Tetra Pak’s Gianmarco Di Eusebio, standard systems typically top out at around 9,000 cartons per hour, meaning that if producers need to hit higher targets, they need to run multiple lines in parallel, adding complexity, occupying floorspace and adding costs to the operation.
At a pilot installation of a new capping machine in Modena, Italy, Tetra Pak has nearly tripled the output compared to conventional machines, allowing the customer to meet demand without expanding its factory floor space or adding new lines.
The new machine, known as the Cap Applicator 40 Speed Hyper, runs at up to 25,000 cartons per hour, defying traditional mechanical limitations. The pilot customer, impressed by the installation’s reliability, performance and flexibility, has dubbed it the “magic machine”.
The enhanced performance is being achieved using a linear transport system combined with PC-based controls. It is using Beckhoff’s XTS linear transport system with “movers” that act as independently controlled servo axes, allowing flexible motion profiles. Combined with Beckhoff’s TwinCat software for motion, vision and PLC tasks, this means that changeovers between cap formats can be handled in software with no need for mechanical refits or line stoppages.
The line occupies just 33m2 of floorspace, improving utilisation by around 40% compared to slower alternatives. Operating costs are said to be 10-15% lower.
The machine uses two parallel 4.5 m XTS tracks, each carrying 55 movers. To sustain the required high speeds, synchronised groups of the movers, operating in batches of six, apply hot-melt adhesive and press the caps onto cartons in perfect alignment. The movers optimise the cap-holder pitch, providing full horizontal and vertical adjustment, thus matching each cap with its pre-laminated hole.
Quality control is provided via a vision system that detects any deviations and adjusts the glue patterns and force profiles automatically, without needing manual stops or wasteful downtime.
This operations are orchestrated by two compact Beckhoff C6032 Industrial PCs, said to deliver millimetre precision and microsecond response times.
High packaging speeds mean little without consistent uptime. Tetra Pak’s new system can adapt instantly to changing product formats, cap types and packaging lines. The process doesn’t just move faster, it runs more reliably too, according to the developers. By replacing complex mechanical parts with software-defined motion, MTBF (mean time between failures) has been doubled.
With its software backbone, the machine also takes advantage of predictive maintenance, real-time monitoring and diagnostic data. Any deviations from the desired performance trigger automatic adjustments, ensuring that minor issues don’t become disruptive breakdowns.
The transparent operation is proving invaluable for maintenance teams looking to gain clear insights into the system’s performance and any wear issues. Scheduled interventions can be planned rather than forced, avoiding costly downtime.
