Compact, connected and automated
Krones launches Ingeniq complete line concept for PET bottling
Krones chose drinktec 2025 for the global launch of Ingeniq, a data-based, fully automated line system for filling non-carbonated water into PET containers. Krones says that the system was designed and developed in response to feedback, customer response and market demand and that it couples low total cost of ownership with consistently high efficiency – and that non-carbonated water is only the beginning.
The name is derived from a combination of ‘ingenuity’ and ‘IQ’ (intelligence quotient). The Ingeniq system consists of modular and standardised components that leverage robotics and artificial intelligence in a design that reduces the overall complexity of the line layout. It is made up of three components: the line itself, which is technologically advanced, modular and future-ready, according to Krones; digital access through Krones Connect and Secure, which affords digital visibility and remote operation; and Lifecycle Alliance, which is described as an “alliance with the customer” in which Krones assumes responsibility for output and life cycle costs in a modularised service agreement.
The line itself
The new digital automation architecture makes it possible to connect efficient individual machines within a line network and maximise automation, from in-house preform manufacture and high-speed filling of non-carbonated water on the ErgoBloc L, through to autonomous material supply logistics and sustainable packaging solutions.
The Prefero preform system, which is at the heart of the line, is a hybrid machine with an electrical mould movement and features a current best-in-class lock-to-lock time of just 1.9 s with a 400 t load. A new, integrated, energy recovery system is claimed to use up to 20 per cent less energy overall than similar machines.
The Prenexo conveyor and buffer system manages material flows between the Prefero injection moulder and the Contiform stretch blow-moulder. Prenexo enables the two machines to be directly bloc-synchronised, thus increasing the level of automation and making the production line more compact, efficient and flexible, Krones says.
The ErgoBloc L wet-end bloc achieves outputs of up to 100,000 containers per hour, on a footprint that is up to 70 per cent smaller than that of a conventional line. Stretch blow-moulding, labelling, filling and capping are all faster and less complicated, thanks to AI-driven process optimisation and quality assurance and a direct connection to the autonomous material handling systems. One example of such an application within the Ingeniq line is the fully automatic reloading, preparing and splicing of label reels without any manual intervention on the operator’s part.
End-of-line solutions
The fully automatic Variopac Pro packer adapts to any packaging needs, whether pads, trays, or wrap-around cartons, with or without film or “only” film-wrapped. The machine’s modular construction makes it flexible enough to handle a wide variety of packaging configurations.
Depending on the task at hand, Modulpal Pro series robots’ individual modular palletising and depalletising components can be combined as needed: for example, to create high-speed palletising specialists, very gentle handling, highly flexible, or even all three at once.
Digital access
The key to digitally networking existing machines or complete lines is Ingeniq’s “Connect and Secure” package. With Connect hardware installed, the line becomes part of Krones’ digital world – visible, connected, secure and remote-maintenance-enabled. The central Krones.world platform gives both the customer and Krones 24/7 access to relevant production data. The combination of digital tools, know-how and collaborative partnership makes it possible to reliably and securely achieve the agreed-upon performance in a joint effort. Compliance with legal requirements such as the Cyber Resilience Act, NIS2, and the EU Data Act is also ensured.
Lifecycle Alliance
The Lifecycle Alliance built into Ingeniq commits Krones to ensure that the agreed-upon level of line efficiency is reached through a joint effort. Krones says it will enable customers to increase output and production reliability, reduce operating costs and downtimes, and improve availability.
Krones offers individually configurable service packages (modular service agreements) and personal consultations with their experts, to make its services optimally aligned and adaptable to meet each customer’s specific requirements.
Markus Tischer, Member of the Executive Board of Krones AG responsible for International Operations and Services, describes the scope of the new concept: “We’re starting the new line concept of the future with a version that fills non-carbonated water into PET containers – but that is just the beginning. Additional container types and product categories will follow. With Ingeniq, Krones is transforming itself from a machine manufacturer into a comprehensive partner for successful production, working together with each customer.”