Bottle capping machines basically come in two categories: inline cappers and rotary chuck-style cappers. These two machines differ from each other in their core designs, as well as in the techniques they apply for closures, such as torque control and the use of a magnetic brake.
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Inline capping machines have side gripping belts that grip the outer edges of the bottles that travel along the conveyor. The gripping belts are speed-matched to the conveyor so that no bottle escapes. As the bottle passes under the cap dispenser, a cap is stripped out by its neck finish. Then, a series of cap tightening wheels spin the cap onto the threaded neck finish as the closure resting on the finish passes through them. Finally, a pair of wheels equipped with friction clutches delivers the desired torque to the capped bottle. The bottle, now tightly capped, is released from the gripping belts.
Rotary chuck-style capping machines have what is called a cap transfer device, which picks out the cap chute and places it in the capping head’s capping chuck, or gripping chuck, if you like. There are two types of pick-and-place mechanisms: a rotary star-wheel with pockets or individual pegs associated with each capping head station.
An in-feed timing screw separates the bottles traveling on the conveyor to match the capping head’s pitch and then transfers them to an in-feed star wheel. They are then transferred to the turret star wheel and placed directly under the capping heads. Then, a rotating capping head holding a cap in its gripping chuck applies the cap to the desired torque. Each capping head has a magnetic clutch that controls the torque. After the cap is applied, the bottle is then released and transferred to the exit conveyor.
That was a brief description of how bottle capping equipment works. Now, let’s talk about the considerations that should be made when choosing the right capping technology for your application.
Inline capping machines are much less costly than rotary chuck-style capping machines.
Inline capping machines have a lower cost for additional change parts that are required to run different sizes of closures and containers. The cap handling equipment consists of only three parts: a sorter, a chute, and a dispenser. There are no cap transfer mechanisms or individual chucks. Changes in cap diameters are made by adjusting the spacing of the tightening wheels.
Inline capping machines take less floor space than rotary capping machines.
This is where chuck-style capping machines beat inline capping machines hands down. They are faster — a lot faster, actually. Chuck clappers use as many as 40 heads and are able to achieve speeds of up to 1,200 bottles per minute (bpm). In comparison, inline cappers have a maximum speed of 200 bpm.
The diameter of the cap that inline cappers can use ranges from 28 millimeters to 70 millimeters. Inline cappers work best with closures of a diameter smaller than 53 millimeters. Rotary cappers, on the other hand, can be used for caps of any diameter since they provide 360 degrees of contact with the cap’s sidewalls. Additionally, they have machined pockets to help maintain the round shapes of the bottle’s neck finish.
Inline cappers are good for round-shaped caps only. Rotary chuck-style cappers can be used for any cap shape: round, oval, square, rectangular, tapered, and reversed tapered.
Rotary chuck-style cappers have precision torque mechanisms, which allows them to apply torque far more accurately than inline cappers, especially in narrow range applications.
Since inline clappers rely on the neck finish to pick off the cap from the cap dispenser, they are limited to caps that are easy to pick off. Rotary cappers have no such limitation.
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Since inline cappers have only side gripping belts they can rely on to keep the container from rotating while applying a cap, there are greater chances of faulty capping. Rotary cappers have no such problem.
Rotary cappers have a huge advantage when it comes to applying closures with Tamper Evident (TE) bands.
Before selecting the ideal liquid filling equipment for your products, you want to ensure your appliances will meet all your specifications. Before investing in new liquid filling machines, consult with the pros at Filamatic. Ask yourself the following questions before meeting with our team members to find the best machine and features for your production needs.
The number of units your facility produces every day will be a crucial factor in deciding which liquid-filling equipment is best.
Beverages like soda and beer will travel quickly through the liquid filling equipment and nozzles, while thicker and more viscous liquids will fill containers more slowly. The liquid’s characteristics, including viscosity, will influence how many bottles can be filled per day. It will also influence whether you can use a timed-flow machine for free-flowing liquids or a piston filler or fillers with a pressurized tank for the more viscous products.
Juices and other liquids can contain pulp or small food particles desired for the finished product. For instance, pulp in orange juice and lemonade or herbs and other spices in tomato sauce. Your valves and pumps must be a specific size to allow the pulp and particulates to flow through unhindered without clogging nozzles or other machine parts.
The container’s size and shape can influence weight variations during filling operations. Due to these characteristics, you might overfill your containers and give away free products in each container. Installing liquid filling equipment with accurate weight variation percentages can help you control product waste.
Understanding the characteristics of your liquid products that will enter the filling and capping machine is essential. This way, you can understand what changes the liquid may undergo as it moves through the equipment parts. A thick liquid that needs to go through long, high-speed production processes can become thinner at the end stage when it’s time to fill bottles. Knowing these factors can influence the type of equipment you choose and your setup, so you can find a solution that does not easily impact the liquid’s characteristics.
Over time, the ingredients in your products may change. Due to these potential changes, you need liquid filling equipment that can be scalable so you won’t have to make drastic changes to your components when making a change.
Liquid buildup in machine components can impact the operation of the liquid filling equipment and the quality of your finished products. Filamatic machines are easy to clean, and our team is available to provide the field service you need to keep your machines well-maintained.
For over 70 years, FILAMATIC has provided a wide range of liquid filling machines to the packaging market. We create flexible, customized solutions for every stage of your business growth. Whether you require a single machine, a complete turnkey fill-cap-label solution, or a fully automated, integrated Monobloc system, we have the liquid filling experience for your project.
For more information on liquid filling, capping, and labeling solutions, please call 866.258. or visit – www.filamatic.com/contact-us.
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