Aleluia Ceramics launches a new state-of-the-art packaging line with Innova Group

The Portuguese ceramic leader Aleluia Ceramics has chosen Innova Group’s technology for a new Stretch Hood packaging line installation. The goal: to automate the end of line at its plant in Ílhavo with more efficient and sustainable systems that provide greater safety and protection for its ceramic products. With this new project, Innova strengthens its position as a leading technological partner in packaging machinery for the ceramics and construction sectors in Portugal, offering advanced automation solutions.

The new packaging installation at Aleluia Ceramics was carried out as part of the technological expansion project at its plant in Ílhavo (Aveiro), which includes a new grinding line and a new end-of-line packaging line. This facility covers an area of 26,500 m² and features three production lines for wall and floor tiles, with a high technological component. The new packaging project is therefore aligned with the company’s goals of technological innovation and sustainability, as it continues to improve its modern Ílhavo plant.

Aleluia’s challenge: automation and efficiency

When planning a new packaging line, Aleluia was looking for new packaging technologies that would allow it to improve load securing and protection, while also reducing energy consumption and the use of consumables. In its other production plants, Aleluia operates packaging lines with shrink hood systems which, although effective in terms of protection and load securing, are an older technology with higher energy consumption and greater film usage. For this reason, Aleluia turned to Innova as a new technological partner to automate its end of line with Stretch Hood, as an alternative to shrink systems due to its advantages in sustainability and energy savings.

Another objective of the new line was to incorporate systems that would improve the securing and stability of Aleluia’s loads for international export. The Portuguese manufacturer therefore sought a combination of packaging systems that would provide greater transport safety, to which Innova responded with a complete solution including strapping, stretch wrapping, and protection with Stretch Hood.

The solution: a packaging line combining Innova systems

Innova designed a packaging line with the combination of systems preferred by the ceramic sector for load securing and protection. The Aleluia project therefore included horizontal strapping for load compaction and overall stability, a ring wrapper for full load containment and securing to the pallet base, and Stretch Hood for total protection of the delicate ceramic goods.

Each component of the line plays a key role in protecting Aleluia’s loads:

• Horizontal Strapping System with Edge Protectors:

The FH | Pro horizontal strapping system is the first station in the line, designed to unify and compact the ceramic load. The system installed at Aleluia includes a four-column frame for greater stability, a load compactor, and an edge protector applicator prior to strapping. The automatic edge protector applicator protects ceramic boxes from strap damage and also improves load uniformity and stability.

In addition, Aleluia’s strapping system is equipped with Innova’s patented ODEN Smartdrive strapping head, a key component developed to deliver greater precision and efficiency in strapping. The ODEN head features advanced electronic technology, with fewer mechanical components and no clutches or sensors, simplifying maintenance tasks.

• Ring Stretch Wrapping System

Next, the AWR | PRO automatic ring wrapping system wraps the load, providing enhanced containment without damaging the boxes. Since the load has already been compacted through horizontal strapping, the ring wrapper ensures full containment across all formats and dimensions, from the base to the top. With the reinforcement rope, it also provides additional stability similar to an extra strap.

• Stretch Hood System

The final packaging station is the SH | Pro Stretch Hood system, which fully covers the load with a single layer of film, protecting the product from external agents. The model installed at Aleluia features a dual film reel holder, allowing it to adapt to different formats and deliver greater productivity, autonomy, and speed in the hooding process.

The Stretch Hood system has been one of the main reasons behind the installation of the new packaging line, as Aleluia selected it for its multiple advantages in protection, waterproofing, safety, sustainability, and cost savings, as well as for the high quality of the final finish.

• Conveyor line and intelligent weighing system

The line is completed with an infeed conveyor system adapted to Aleluia’s handling equipment, along with a pallet centering system. It also includes a special conveyor for the Stretch Hood station and an outfeed and pallet accumulation line with an integrated weighing system connected to the labeling system.

The weighing system sends real-time information about the final load weight to the labeling system, enabling immediate data printing. In this way, Aleluia further automates and optimizes its logistics management.

Results and project conclusion

In conclusion, the new packaging line has enabled Aleluia Ceramics to optimize its end of line and significantly improve operational efficiency, achieving greater load stability and reducing transport-related incidents. In addition, the incorporation of the Stretch Hood system has reduced both energy consumption and material usage compared to shrink hood systems, aligning with the company’s sustainability objectives. This technological upgrade also represents an improvement in the quality of the final packaging, offering a more uniform, secure, and resistant presentation against external agents.

Ultimately, this project reinforces Aleluia Ceramics’ commitment to technological innovation and positions Innova Group as a strategic partner capable of developing complete, efficient solutions tailored to the specific needs of the ceramic sector. The collaboration between both companies consolidates a successful model based on continuous improvement, sustainability, and operational excellence.

Thank you, Aleluia Ceramics, for trusting Innova Group with this project!