Aerosol Cap Packer – Innovative Automation for the Cap Manufacturing Industry

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For our client, a leading European manufacturer of aerosol caps, we developed a comprehensive automation solution for the cap packing process – the Cap Packer. This project was created in response to specific production challenges faced by the client, who observed that traditional packing methods were causing serious issues during cap application. Drawing on our experience, we designed a machine that solved these problems and significantly improved production efficiency.

Client: Leading European Aerosol Cap Manufacturer
Project date: Q1, 2020

Project goal: Automation of the cap packing process, elimination of cap deformation, and increased production efficiency.

The Challenge:

One of the European market leaders in aerosol cap production approached us to solve a persistent issue of cap deformation, where caps would break during application onto cans, resulting in:

High number of complaints: Damaged caps affected the quality of the final product, leading to increased customer complaints and lower satisfaction.
Logistical issues: Improper packing led to wasted space in boxes, driving up transport and storage costs.
Financial losses: Increased complaint rates and the need for manual packing negatively impacted production efficiency and profitability.

Work progress

Our Solution:

Based on our analysis, we designed a modern, high-performance packing machine that not only arranges caps in an orderly fashion but also adjusts the packing speed and layout according to customer specifications. The Cap Packer operates at a capacity of 60 caps per minute, with easy scalability up to 100 caps per minute.

The technology we implemented includes:

Precise layer-by-layer cap arrangement – critical for even load distribution in boxes, minimizing the risk of deformation.
Cap cooling system – enables warm caps to cool before packing, significantly reducing their plasticity and susceptibility to damage.
Interchangeable suction gripper – designed for quick and easy adjustment to different cap sizes, making the machine universal and suitable for packing various cap types.
Automated cap counting process – we implemented a system of sensors and actuators that count the caps and arrange them into even rows per layer. Once a layer is complete, the caps are transferred into a box using a specialized gripper.

Workplace Safety:

Safety was a key element of the project:

Safety systems: The machine is equipped with protective guards and emergency stop switches that immediately halt operations in case of unforeseen events.
Improved working conditions: Automation reduced the need for manual handling, increasing worker safety and reducing the risk of accidents.
Compliance with regulations: The machine meets all requirements of the European Machinery Directive and bears the CE mark, ensuring safe long-term use in accordance with the highest safety standards.

Result

Results:

With the implementation of our machine, the client achieved full automation of a previously manual packing process. The benefits of our solution included:

Elimination of complaints: The issue of deformed caps was fully resolved, drastically reducing the number of customer complaints.
Increased efficiency: The machine operates at 60 caps per minute, expandable to 100, allowing flexible adaptation to production demands.
Logistics savings: Thanks to organized packing, the client can fit 23% more caps per box, significantly reducing transportation and storage costs.
Improved safety: Full process automation reduced manual operations, directly improving employee safety and lowering accident risks. The machine complies with all machinery directive requirements and CE standards, ensuring safe long-term operation.

Our Approach:

In every project, we leverage our extensive experience by implementing proven and optimized solutions. This case demonstrates how crucial thorough analysis of production challenges is, along with the ability to adapt technology to the client’s needs. Thanks to our solutions, we support not only aerosol manufacturers but also component producers, offering machines that meet even the most demanding production requirements.

Machines used in the project:

Automatic Cap Stacker WCZ
Cap Sorter
Cap Elevator

See project video

Need a solution for yourself? Looking for a competent partner?

Contact our engineers! We will certainly tailor the right device for your line. Email us at sales@solmatic.pl or call +48 32 307 07 41

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