Suitable for lines up to 54.000 bottles/hour
Electronic Handle Applicator XHE
High-speed application of adhesive handles, with real performance up to 100 packs/min per lane and 200 packs/min in dual-lane operation. Patented arm and progressive transients for better line stability.
- 100 packs/min Single lane
- 200 packs/min Dual lane
- No compressed air In high-speed XHE configurations
Interactive XHE Platform
XHE Electronic Handle Applicator
Select a module from the control panel to highlight it in the technical drawing and immediately open the related data sheet, without leaving the page.
Technical sheet of the selected module
System Description
The XHE Electronic Handle Applicator is designed to apply adhesive handles at high throughput while maintaining process continuity and application precision.
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It reaches speeds of 100 packs/min in single-lane mode and 200 packs/min in dual-lane mode, with 3x2 packs (bottles of 1.5 L) and optimized handle length. In dual-lane configuration, the two channels operate independently: the line stays balanced and one lane can remain idle during temporary transitions to single-lane formats.
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For performance benchmarking, data measured on real production lines are essential, not short laboratory tests. Speed must always be evaluated together with pack format and handle drop depth relative to bottle shoulder, a parameter that directly affects transport stability and holding performance.
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The fastest XHE models do not require compressed air: movement is fully electric, with benefits in reliability, repeatability, synchronization, and accuracy across different speeds.
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To handle high throughput, the software integrates dedicated algorithms that stabilize handle application during transients (start-up, stop, and speed variations), improving smooth integration with other line units.
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XHE is generally configured with three speed-change triggers, activated both at infeed (shrink-wrapper side) and outfeed (palletizer side), to reduce "start" and "stop" cycles and improve component life and production efficiency.
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The application arm (patented) uses a roto-translational motion that avoids reversing the rotation direction of the two servomotors. Eliminating stops during cycles reduces wear on mechanical components, especially planetary gearboxes and brushless motors.
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XHE maintains smooth and progressive motion, particularly relevant when the application arm runs above 50-60 packs/min.
Product Guides
The XHE handle applicator integrates an infeed gantry product-guide system with mechanical transmission. The main available adjustments are:
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Handwheel with mechanical position indicator: target values are stored in the format recipe and shown on the display.
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Motorized adjustment with mechanical position indicator: target values remain saved in the recipe and are immediately available on the display.
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Motorized adjustment with electronic position indicator: adjustment is managed from the display using open/close buttons, with live value display until the target is reached.
Depending on the packaging line, guides can be configured as follows:
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Self-centering (fixed pack center distance): one actuator simultaneously narrows or widens guides on lane "A" and lane "B".
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Fixed inner guides and adjustable outer guides, also with single-actuator control.
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Independently adjustable inner and outer guides (see animation), with two dedicated actuators: one for outer guides and one for inner guides.
The guides use a stainless-steel "C" support frame and four crossed rows of large-diameter rollers. This configuration reduces contact between shrink film and fixed parts, limiting scratches and undesired pack rotation.
On multi-format lines, lower-cost solutions are not recommended: the risk is loss of conveyor parallelism and reduced centering accuracy with the application arm, causing premature wear of modular chains and belts due to lateral pushing forces.
Customizations are available according to line requirements; our technical office can help define the most suitable configuration.
Brake Conveyor (Metering)
The Brake conveyor has a dual function: absorbing upstream pushing forces and metering packs toward the handle applicator. Its peripheral speed dynamically determines machine speed in packs/min.
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During line design, it is recommended to install, upstream, an accumulation conveyor of about 2.5 meters and a dedicated brake conveyor, in order to isolate the machine from upstream conveyor pushes.
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These elements, also available from Decimo as an integrated machine supply, work together with line sensors to modulate upstream and downstream speed, improving operating continuity and reducing stops/restarts.
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The metering conveyor is not designed to absorb uncontrolled variable pushing intensity: strong force variations may cause abnormal behavior during metering.
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The Brake Conveyor is equipped with an asynchronous motor with encoder, controlled by a closed-loop inverter (see animation): an effective solution during transients (stop, start, and speed changes), with controlled, precise, and repeatable ramps.
Spacer Conveyor
The Spacer Conveyor is a key component of the XHE handle applicator: it receives packs from the metering conveyor and sets them at the correct handle-application pitch.
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To guarantee maximum pitch accuracy, it is equipped with a servomotor and dedicated sensors that measure distance between consecutive packs. When measured distance is outside tolerance, control corrects spacing by adjusting conveyor peripheral speed.
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This logic ensures reliable behavior also during transients (stops, restarts, and speed changes), keeping machine pace aligned with real line conditions.
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Transfer to the next conveyor (Handle Conveyor) occurs at constant speed, reducing wear and stress on the modular rubber chain.
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Conveyor-to-conveyor transfer is supported by stainless-steel rollers on bearings, designed to ensure regular pack transfer between modules.
Handle Conveyor
The Handle Conveyor uses a modular chain with rubber inserts to keep packs stable during transport and handle application.
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As with the Brake Conveyor, it is equipped with an asynchronous motor with encoder and closed-loop inverter (see animation), a key solution for maintaining synchronization with upstream conveyors during transients.
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Conveyor motor motion also drives the master encoder that controls machine servomotor positions: the more linear the rotation, the smoother the overall machine movement.
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The master encoder is directly connected to the conveyor motor shaft to guarantee maximum reference accuracy throughout the cycle.
Machine Description
The frame is made of stainless steel with large-section welded tubular profiles: a rigid and robust structure developed according to project-specific requirements.
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Guards (doors and tunnels) use anodized aluminum frames with 5 mm transparent polycarbonate. Doors are equipped with interlocked safety limit switches, as required by standards, to stop moving parts in emergency conditions.
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The dual-lane configuration includes 2 HMI displays, one per side: this avoids operator-panel arm obstruction and improves accessibility around the machine. In case of one display failure, operation can continue on the other while replacement is arranged.
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The upper belt device with sponge support accompanies the pack during the cycle, acting on outer bottles. It is servo-driven to remain synchronized with the master handle conveyor and to cover a wide range of formats.
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In recent models, the handle is applied symmetrically on the pack even when bundles are not perfectly squared (for example, rhomboid section or slight infeed rotation).
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Start-up, stop, and speed changes are managed progressively, to maintain handle centering even during prolonged transients.
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Both the application arm and the adhesive tape cutting blade motion are servo-driven.
The XHE handle applicator machine
Image gallery of the XHE Electronic Handle Applicator: focus on system configuration, application head, HMI, construction details, and wiring.
- All
- System
- Head
- HMI
- Details
- Wiring
XHE in action
Select the video to view the general presentation or a functional focus of the XHE Electronic Handle Applicator.
Data sheet XHE
Select the model to view layout, technical data, and optional equipment for the XHE Electronic Handle Applicator.
Selected model
XHE-1 | Single lane
Layout files, technical data, and optional equipment of the XHE-1 Electronic Handle Applicator for single-lane configuration. For additional information or clarifications, contact our technical office.
Layout XHE-1
The XHE-1 Electronic Handle Applicator layout (single lane) is available in DXF format. Click the drawing to download it and use it in your line layout.
The full footprint also includes the external electrical cabinet and the handle-forming and handle-feeding unit. If you need the complete project layout, contact us and we will provide all required material.
If you have specific constraints, such as limited space or special product formats, we can:
- Carry out feasibility studies
- Propose customized solutions
- Recommend the machine best suited to your needs both in functional and economic terms
Technical data
Technical data relating to the XHE-1 handle applicator machine (single lane).
The following data are related to the XHE-1 100 from 100 packs/min. If you are interested in data from the same machine series (XHE) but with lower maximum speed such as 70 packs/min or 40 packs/min contact us and we will provide you with all the necessary data.
- Machine model:
- XHE
- Maximum production:
- 36.000 bottles/hour
- Speed per lane:
- 100 packs/min
- Number of lanes:
- 1
- Electric power:
- 7,5 kWh
- Air pressure:
- No compressed air required in the XHE-1-100 configuration at 100 packs/min
- Air flow:
- No compressed air required in the XHE-1-100 configuration at 100 packs/min
- Power supply:
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380-415 V
3PH-N-PE
50 Hz
Optional equipment
Below is the optional equipment list for the XHE Electronic Handle Applicator. Optional items preceded by are standard. Optional items must be selected during machine order definition.
Standard
Optional
When the product format changes, the adjustable elements of the machine must be repositioned. This operation can be carried out in different ways:
- Manual adjustment with handwheel and mechanical position indicator. During recipe change, target values are shown on the HMI and applied using the handwheel.
- Semi-automatic adjustment with motorized control, display buttons, and digital position indicator.
When the product format changes, the adjustable elements of the machine must be repositioned. This operation can be carried out in different ways:
- Manual adjustment with handwheel and mechanical position indicator. During recipe change, target values are shown on the HMI and applied using the handwheel.
- Semi-automatic adjustment with motorized control, display buttons, and digital position indicator.
- Automatic adjustment, with the same motorized system and a single "start adjustment" command.
When the product format changes, the adjustable elements of the machine must be repositioned. This operation can be carried out in different ways:
- Semi-automatic adjustment with motorized control, display buttons, and digital position indicator.
- Automatic adjustment, with the same motorized system and a single "start adjustment" command.
Remote assistance on PLC or HMI reduces intervention time and improves service continuity.
Remote assistance contracts allow the purchase of a number of hours to be spent within a year, 360 days from the time of subscription, with remote interventions.
The types of devices available are:
- Router LAN-to-LAN
- Router Wi-Fi-to-LAN
- Router 4G-to-LAN
To allow technicians to view the machine remotely, a PoE camera with microSD memory card is available as an option.
The camera is supplied with a 10 m Ethernet cable for service use. One end connects to the camera and the other to the dedicated connector in the push-button panel or inside the electrical cabinet on the PoE switch.
Using the free software provided by the camera manufacturer, operators can view the stream and manage recordings. The same tools are also available as an app for smartphones and tablets.
- PoE camera with microSD memory card
The handle arch forming device is used to create a stable curved handle profile, making manual gripping easier for the operator.
This option is mainly required for 4x2 formats, where the tape does not rest on the central bottle caps as it does in 3x2 formats and the arch would otherwise be reduced. There are two types depending on the speed of the machine:
- For speeds up to 40 packs/min per lane, an alternating translational motion device is required
- For speeds up to 70 packs/min per lane, a continuous rotary motion device is required
Electrical cabinet cooling can be implemented in two ways:
- Fan cooling
- Electrical air-conditioning unit (recommended)
The compact DIN-rail UPS protects the PLC against voltage drops and power outages.
The 24 VDC power supply is backed up for a defined period in case of voltage drops or power outages. The unit is compact, lightweight, and equipped with a long-life lithium-ion battery.
- UPS for PLC
The XHE electronic handle applicator can be supplied with the following HMI display sizes:
- 7"
- 10"
Selected model
XHE-2 | Dual lane
Layout files, technical data, and optional equipment of the XHE-2 Electronic Handle Applicator for dual-lane configuration. For additional information or clarifications, contact our technical office.
Layout XHE-2
The XHE-2 Electronic Handle Applicator layout (double lane) is available in DXF format. Click the drawing to download it and use it in your line layout.
The full layout also includes the external electrical cabinet, handle-forming unit, and handle power unit (one per lane). If you need a complete project layout or a custom arrangement for constrained spaces or specific product formats, we can:
- Carry out feasibility studies
- Propose customized solutions
- Recommend the machine best suited to your needs both in functional and economic terms
Technical data
Technical data relating to the XHE-2 handle applicator machine (double lane).
The following data are related to the XHE-100-2 from 100 packs/min. If you are interested in data from the same machine series (XHE) but with lower maximum speed such as 70 packs/min or 40 packs/min contact us and we will provide you with all the necessary data.
- Machine model:
- XHE
- Maximum production:
- 72.000 bottles/hour
- Speed per lane:
- 100 packs/min
- Number of lanes:
- 2
- Electric power:
- 12,5 kWh
- Air pressure:
- No compressed air required in the XHE-2-100 configuration at 100 packs/min
- Air flow:
- No compressed air required in the XHE-2-100 configuration at 100 packs/min
- Power supply:
-
380-415 V
3PH-N-PE
50 Hz
Optional equipment
Below is the optional equipment list for the XHE Electronic Handle Applicator. Optional items preceded by are standard. Optional items must be selected during machine order definition.
Standard
Optional
When the product format changes, the adjustable elements of the machine must be repositioned. This operation can be carried out in different ways:
- Manual adjustment with handwheel and mechanical position indicator. During recipe change, target values are shown on the HMI and applied using the handwheel.
- Semi-automatic adjustment with motorized control, display buttons, and digital position indicator.
When the product format changes, the adjustable elements of the machine must be repositioned. This operation can be carried out in different ways:
- Manual adjustment with handwheel and mechanical position indicator. During recipe change, target values are shown on the HMI and applied using the handwheel.
- Semi-automatic adjustment with motorized control, display buttons, and digital position indicator.
- Automatic adjustment, with the same motorized system and a single "start adjustment" command.
When the product format changes, the adjustable elements of the machine must be repositioned. This operation can be carried out in different ways:
- Semi-automatic adjustment with motorized control, display buttons, and digital position indicator.
- Automatic adjustment, with the same motorized system and a single "start adjustment" command.
Remote assistance on PLC or HMI reduces intervention time and improves service continuity.
Remote assistance contracts allow the purchase of a number of hours to be spent within a year, 360 days from the time of subscription, with remote interventions.
The types of devices available are:
- Router LAN-to-LAN
- Router Wi-Fi-to-LAN
- Router 4G-to-LAN
To allow technicians to view the machine remotely, a PoE camera with microSD memory card is available as an option.
The camera is supplied with a 10 m Ethernet cable for service use. One end connects to the camera and the other to the dedicated connector in the push-button panel or inside the electrical cabinet on the PoE switch.
Using the free software provided by the camera manufacturer, operators can view the stream and manage recordings. The same tools are also available as an app for smartphones and tablets.
- PoE camera with microSD memory card
The handle arch forming device is used to create a stable curved handle profile, making manual gripping easier for the operator.
This option is mainly required for 4x2 formats, where the tape does not rest on the central bottle caps as it does in 3x2 formats and the arch would otherwise be reduced. There are two types depending on the speed of the machine:
- For speeds up to 40 packs/min per lane, an alternating translational motion device is required
- For speeds up to 70 packs/min per lane, a continuous rotary motion device is required
Electrical cabinet cooling can be implemented in two ways:
- Fan cooling
- Electrical air-conditioning unit (recommended)
The compact DIN-rail UPS protects the PLC against voltage drops and power outages.
The 24 VDC power supply is backed up for a defined period in case of voltage drops or power outages. The unit is compact, lightweight, and equipped with a long-life lithium-ion battery.
- UPS for PLC
The XHE electronic handle applicator can be supplied with the following HMI display sizes:
- 7"
- 10"
Production changeover
Fast changeover based on three systems and three adjustment modes.
- Infeed product guides
- Application head width
- Application head height
- Manual
- Semi-automatic
- Automatic
Setpoint values are saved per recipe and recalled from the machine display: manual mode uses cranks and indicators, semi-automatic mode uses motors and push buttons, and automatic mode uses motors and encoders.
Lateral Product Guides
Quick guide setup according to the host line, with centered and stable configuration across format changes.
- Self-centering setup with synchronized movement of lanes A/B.
- Versions with adjustable inner/outer guides using one or two actuators.
Guides can be configured as self-centering (fixed center distance), with fixed inner and adjustable outer guides, or with independent adjustment of inner and outer guides. In the independent setup, two actuators manage movements separately.
Application Head Width
Fast adjustment of the distance between heads, including reduced center distances, to speed up format changes.
- Symmetrical adjustment with a single actuator.
- Independent adjustment with two dedicated actuators.
In dual-lane lines, head width can be adjusted in symmetrical or independent mode. Independent configuration allows separate positioning of Head "A" and Head "B" according to recipe targets.
Application Head Height
Height control via geared motor and display control, with dynamic position value always visible during adjustment.
- Position sensor + limit switches between minimum and maximum values.
- System already included in the machine base configuration.
Height adjustment of the Head (single lane) or Heads (dual lane) is managed by a geared motor from a dedicated display page. Each recipe shows the format target and dynamic current value, reducing setup errors and changeover time.
Human-Machine Interface
The HMI of the XHE Electronic Handle Applicator is designed for daily operations: smart interface, dedicated pages, updatable technical manual, and guided procedures to speed up setup and maintenance.
In dual-lane configuration, 2 HMI displays are available, one on each machine side: this reduces footprint and pushbutton-arm interference while preserving operational continuity even if one panel is stopped.
- HMI manual available in PDF, CHM, and HTML5 formats
- HTML5 access from customer assistance portal, including smartphones
- Step-by-step procedures for recipe change, axis referencing, and recurring operations
- Standard 7" display with 10" and larger options
Home Page
The Home Page provides quick links to the most common operations and immediate visibility of priority machine information and states.
Open screen
Machine States
Machines are programmed according to the PackML standard developed by OMAC for consistent, readable state management.
Open screen
Recipe Book
Dedicated page for production formats: recipes can be saved and quickly recalled in case of changeovers or setup errors.
Open screen
Jog Arm
Section dedicated to jog movement of the applicator arm, with clear graphics and immediate adjustment commands.
Open screen
Cycle Phases
Phase diagram with sensor names and states involved in the machine cycle; operating values are expressed in crank degrees.
Open screen
Inverter Status
Dedicated inverter view with read-only parameters such as frequency and conveyor peripheral speed (vector inverter with closed-loop control).
Open screen
Drive Status
Servo-drive diagnostic page with axis status and error codes, useful for quick checks and maintenance support.
Open screen
Pack Parameters
Example page for format parameter setup, with intuitive graphics and sensor references related to each adjustment.
Open screen
Sensor Layout
Graphic layout of sensor distribution along machine and line, useful for quick checks and intervention-point identification.
Open screenTechnical documentation
Technical documentation gathers design, manufacturing, and operating information for the product, including all content required to demonstrate compliance with applicable requirements. Machinery Directive 2006/42/EC gives specific relevance to the documentation that must accompany the machine, namely the mandatory documents the manufacturer must prepare before market placement.
HMI user manual (Human-Machine Interface)
The user manual is essential for machine control. It is developed in detail and updated over time using customer feedback. It is available online in multiple formats for quick consultation.
Smart Pages
The interface is designed to be fast and intuitive, with clear links and graphics to support operators. Each command is associated with an icon representing the related action.
Procedure
The manual includes operating procedures for the most common tasks, such as recipe change and applicator arm reset. Each procedure is step-by-step, with visual indicators showing which buttons to press in sequence.
Problem solving
In addition to lifecycle management, warning messages are generated when components approach manufacturer life limits (for example, solenoid valves), and include guided troubleshooting instructions.
User manual files
The user manual is available in different formats:
HTML5 format: this is the most practical version because it is available online through the customer portal (username and password) and can also be viewed on smartphones.
Use and maintenance manual
Manual quality is often underestimated. It is not only a legal requirement: when a machine is shipped abroad, documentation must be written and translated accurately to avoid misinterpretation. Current practice follows the Machinery Directive framework, which clearly defines the information an instruction manual must provide to the end user.
Clear information
Images are prepared carefully to make information as clear and immediate as possible.
Clear and accessible language
The content is written in short, clear sentences so that instructions and safety requirements are easy to understand for all operators.
Illustration of the technical documentation
"A picture is worth a thousand words." To improve readability, the manual includes numerous illustrations created with dedicated software.
Language translation
The manual translation is commissioned to an external company specialized in translations of technical manuals.
User manual review and updates
The manual is reviewed and updated whenever machine configurations change, including component replacements. For this reason, an always-updated online format is provided.
Pay attention to the rules
Decimo works with external specialists who continuously review applicable standards and regulatory updates.
Spare parts manual
Our after-sales service supports customers from technical phone assistance to spare parts supply, with the objective of delivering fast and reliable support over the full machine lifecycle.
Project catalogue
The spare parts catalogue is developed specifically for each project. We do not provide generic catalogues that do not represent the actual installed components.
Illustrations
All catalogue illustrations are produced from exploded CAD assemblies (instead of unclear photos) to avoid errors during ordering.
Codes
Each component in each drawing has a numerical reference linked to a table containing item number, purchase code, description, and quantity.
Availability review and periodic updating of the manual
The spare parts catalogue is available online for customers. For ordering, always refer to the latest revision, as updates are continuous.
Online spare parts catalogue
An extended online version will be progressively made available, including interactive ordering features aligned with customer pricing conditions.
Wiring diagrams and technical file
Wiring diagrams are developed in accordance with current standards using professional software. The package also includes technical data sheets and manuals of relevant components.
Multilingual
The diagrams are delivered in digital format, usually PDF, and support multiple languages. Just select the required language from the menu.
Electrical cabinet layout
The document includes 2D and 3D electrical cabinet layouts with realistic component representation.
Reports
The document includes several reports such as cable lists and references. The bill of materials is the key report and summarizes all used components.
Images
An image is shown next to each symbol to make interpretation easier for operators and maintenance staff.
Pneumatic diagrams
The pneumatic diagrams comply with current regulations and are produced with professional software.
Language versions
Pneumatic diagrams are supplied in the customer's selected language.
Material report
The document includes a complete list of all components used in the project.
Detailed representation
The pneumatic diagrams include pipe sections, line colors, connection types, air distributors, and additional technical details.
Technical file
For machine safety compliance, manufacturers must keep complete technical documentation covering design and production. This documentation must be available to competent authorities and demonstrates conformity with applicable standards.
Declaration of conformity
The declaration of conformity is a mandatory document certifying that the product complies with applicable standards and can be placed on the market.
CE marking
Many products require CE marking before being sold in the EU. CE marking certifies that the manufacturer has assessed the product against EU requirements for safety, health, and environmental protection.
Certificates, tests, and verification reports
All tests and verification reports are documented in the technical file.
Performance Level
Performance Level evaluates the reliability and effectiveness of a safety function under defined operating conditions.
Performance Level classification
A safety function is implemented in the machine and related devices to reduce risk in case of faults. It is typically managed through dedicated safety logic and monitored signals. The objective is to reduce hazardous conditions for operators as far as reasonably possible. Performance Level is classified from A to E, where E represents the highest safety performance and A the lowest.
Sysmac platform
Powerful and robust automation platform equipped with the NJ controller, integrating motion, logic, safety, networking, and visual inspection. Sysmac Studio includes configuration, programming, simulation, and monitoring, while EtherCAT provides high-speed control of motion, vision, sensors, and actuators.
- Single control architecture for the entire machine or production cell.
- High-speed network with update time up to 100 μs and jitter below 1 μs.
- A single software environment for machine control and configuration, with one connection point for efficient development and commissioning.