How Danfoss iC7-Automation Perfected Production Lines for Ave Technologies

The Danfoss iC7-Automation range is a future-ready variable speed drive designed to deliver precise motion control, exceptional flexibility and faultless performance for demanding industrial applications. Available from LED Controls, your trusted Danfoss Drives Authorised Partner.

Ave Technologies - Danfoss Automation Case Study

Danfoss iC7-Automation drives helped Italian machine builder Ave Technologies modernise their bottling lines by replacing traditional mechanical synchronisation with an intelligent electronic solution.

The Problem: Complex Configurations with Limited Flexibility

One of Ave Technologies' vinegar bottling lines featured multiple rotating stations including:

• Bottle cleaning
• Filling
• Aluminium cap application
• Plastic cap application

Traditionally, these stations were synchronised using a complex mechanical and pneumatic transmission system. This arrangement created several challenges:

• Machine format changes required lengthy manual adjustments.
• Operators could spend days reconfiguring equipment for different bottle sizes.
• Mechanical couplings increased maintenance requirements.
• Future production increases would place additional strain on the system.
• Overall machine flexibility was limited.

Ave Technologies wanted a solution that simplified synchronisation without introducing the complexity and cost of a full servo motion system.

The Solution: Danfoss iC7-Automation

Ave Technologies chose the Danfoss iC7-Automation variable speed drive with integrated motion functionality. Using standard asynchronous motors combined with encoder feedback, the drives electronically synchronise each section of the machine while eliminating much of the mechanical transmission hardware. This results in a cleaner, simpler and more flexible machine design that maintains highly accurate positioning while reducing engineering complexity.

Key Benefits of iC7-Automation

• Electronic synchronisation using standard induction motors
• Integrated motion control within the drive
• Minimal PLC software modifications
• Reduced PLC processing requirements
• Simplified machine commissioning
• Lower maintenance requirements
• Reduced spare parts inventory
• Compatibility with multiple encoder types
• Remote diagnostics using MyDrive® Insight
• Built-in cybersecurity features for future-ready automation systems

Outstanding Synchronisation Accuracy

The project delivered positioning accuracy of approximately 0.3 to 0.4 mm, comfortably exceeding the original design objectives while simplifying overall machine operation. For operators, changing production formats became significantly easier: Rather than manually adjusting mechanical components, they simply select the appropriate bottle recipe and allow the machine to position itself automatically. This reduces downtime, minimises the potential for operator error and enables faster production changeovers.

Designed for Future Machine Development

Another major advantage for Ave Technologies was the ability to standardise this approach across future machine designs. Because synchronisation is handled within the drive itself, engineers can develop scalable machine platforms without relying on increasingly complex mechanical transmission systems.

The iC7-Automation platform also supports future developments including permanent magnet motors, enhanced cybersecurity requirements and advanced remote diagnostics, helping OEMs protect their machine designs for years to come.

Why Choose Danfoss iC7-Automation?

The Danfoss iC7-Automation range is designed for high-performance industrial automation where precision, flexibility and uptime are critical. Typical applications include:

• Packaging machinery
• Bottling and filling lines
• Conveyor systems
• Material handling equipment
• Food and beverage manufacturing
• General machine automation

Its integrated motion capabilities enable manufacturers to achieve servo-like performance in many applications whilst reducing hardware complexity and lowering the total cost of ownership.

Danfoss Drives from LED Controls

As an Official Danfoss Drives Authorised Partner and distributor, LED Controls supplies the complete Danfoss Drives portfolio, including the innovative iC7-Automation. Browse our Danfoss Drives range or contact the LED Controls team today to discuss how the iC7-Automation platform can improve the performance, flexibility and reliability of your automation systems.