Liquid packaging machines: the benefits of automating the capping process
It’s a pretty safe bet that most bottlers who hand-cork bottles to prepare them for sale aren’t looking forward to the process. Not only can it be tedious and time consuming when the numbers are large enough, it can present a danger to those who twist, push, and squeeze in the form of repetitive motion injuries. Additionally, some closures are simply not conducive to manual sealing, such as ROPP closures that require knives to screw the closures on when applied. At a certain point, capping machinery may truly become a necessity for packers, and the benefits of such equipment will remain much the same whether semi-automatic equipment or fully automated bottle cappers are used. There are other benefits to using capping machinery as well, some of which are detailed below.
1. Consistency and reliability
Whether you use semi-automatic or automatic capping equipment, one of the biggest benefits is that bottles and other containers will be sealed consistently every cycle. In addition to the fact that human hands simply won’t tighten all caps the same, extended time spent sealing bottles can lead to fatigue and, if we’re being honest, boredom, which then leads to inconsistent and unreliable capping. . Automatic capping machines are built to cap each and every container in the same way, whether by applying torque, applying pressure, or otherwise sealing. Of course, semi-automatic capping machines will still use an operator to assist in the process, but the actual squeezing, pushing or sealing will be done by the machine itself. The automated machines will only require initial setup by an operator, as cap delivery systems will be used to present the closures to the bottles.
2. Capping speed
Given enough time, or broken into enough shifts, manual capping can be a fairly consistent and reliable method of preparing product for the shelf. However, as the numbers rise, taking the time to avoid fatigue, boredom, and injury would ultimately lead to an inefficient limiting process. Bottle capping machines will generally increase speed over manual capping, with automatic machinery reaching speeds of up to 100 bottles per minute or more. Almost every packer looking for an automatic capping machine will expect higher performance, but there are some exceptions to this rule. As noted above, capping machines can bring consistency and reliability to the process, and some tabletop and manual cappers will be used for these purposes, even without a significant increase in speed. However, more often than not, the speed with which sealing can be accomplished will be one of the main benefits of using capping machinery.
3. Simple operation
Although things can’t get much simpler than screwing on a cap or pushing in a cork, good capping machines are designed to make things easy for the operator. Semi-automatic equipment will usually require the operator to place the cap on the bottles and slide the combination into place to allow the machine to perform the sealing. Automatic machinery will require some initial setup and bottle-to-bottle changeover, but once up and running it usually only requires the operator to make sure closures are available to the machine from time to time. The best capping machines will require no tools to set whenever possible, relying on hand cranks and knobs to make adjustments. While unique containers and closures may result in some exceptions to tool-less set-up and adjustment, the ability for almost anyone to operate capping machinery is a third benefit for packers.
4. Versatility
Very rarely will a company package a single product in a single container, using only one type of lid or closure. Therefore, capping machinery must be versatile enough to handle a variety of cap shapes and sizes. For example, screw capping machines offer a solution for screw caps, whether it is flat caps, flip caps or even trigger sprays, a single screw capper can be built to handle a variety of screw caps. Some machines can even be combined to handle different types of closures, such as a spindle and a snap capper. This machine can tighten continuous thread caps or apply pressure for snap type caps. The versatility of a capping machine is a benefit that allows for a cost effective and efficient solution to the capping process.
5. Integration
In the packaging industry, there are manufacturers that specialize in a specific type of machine, whether it is a liquid filler, capping machine, labeler, or other equipment. Capping machinery can be integrated with existing packaging lines as long as space is available for the equipment. Some packagers will also automate the processes step by step. Processes like filling or labeling may already be automated when a packer looks for a capping machine. The advantage of being able to integrate capping machinery into an existing system is that packers can grow and automate at their own pace, which will be different for almost every company.
The benefits of adding automation to the capping process will vary from project to project, as will the amount of automation added, but the benefits listed above will often be the motivating factors for change. An analysis of packaging, closures, product demand, space and budget should always be done for any project when looking for the best capping solution, which can add efficiency, speed, reliability and much more to the packaging process as a whole.
