Our Approach

We began with a detailed analysis of the client’s specifications and requirements. Our goal was not only to achieve high output, but also to ensure maximum flexibility. A key component of the project was the gas filling machine, which had to be capable of dosing different gases into the same can within a single cycle. We implemented variable stroke drive technology, which allows the filling process to adapt depending on the gas mixture. Unlike standard rotary gas filling modules—commonly used for high-capacity production—this approach provides more flexibility, as rotary modules can typically dose only one type of gas. In this case, we delivered an indexing system that allows for a more flexible configuration.

Research and Testing

Throughout the project, we placed particular emphasis on research and testing to ensure the highest quality and efficiency. We carried out extensive testing of different gas dosing methods and precisely determined the required number of gas filling modules based on empirical data on processing times and the client’s valve specifications.

Our comprehensive R&D approach allows us to continuously improve our solutions, enabling us to deliver production lines that not only meet the client’s expectations but exceed them in terms of performance and reliability.

Testing of L-shaped Valves

One of the key challenges was to develop a solution for sorting and positioning “L”-shaped (pipe-type) valves, which can only be placed in the can at a specific angle. Thanks to advanced 3D prototypes, simulations, and testing, we were able to ensure that our machine would operate with precision and reliability. We implemented a precise valve sorting and positioning system prior to insertion, making us one of the few companies in the world to have successfully built a machine capable of reliably handling and inserting this type of valve.

Gas Dosing Precision

During tests of various gas dosing methods, we confirmed our calculations showing that multi-step dosing is the most effective approach for precise process control. By using different configurations (1/2, 2/2, 2/4, 3/3), we ensured optimal filling speed while maintaining full flexibility. The intuitive control system enables operators to easily adjust the machine’s parameters to meet production requirements.

Key Technological Solutions in This Line

• Variable Stroke Drive – Enables flexible dosing of different gases within a single production cycle, significantly expanding configuration options and adapting the machine to various gas types.
• Flexible Gas Dosing – The 1/2, 2/2, 2/4, 3/3 configurations allow the operating mode to be precisely adapted to product requirements, enhancing output without compromising flexibility.
• Modern Automatic Checkweigher – Designed for large gas volumes, this device ensures high stability and measurement accuracy even at high production speeds. With a wider base and optimized can feed angle, it allows for precise weight control, significantly improving product quality and production safety.
• Flat Cap Inserter – We developed a dedicated cap inserter to replace standard prism-style cappers. This solution improves capping precision for threaded valves and was necessary due to the specific design of the caps used by the client in the gas industry.

Workplace Safety

Safety was a critical element of the project, especially due to the handling of flammable gases:

• Safety Systems – The line is equipped with multiple sensors monitoring production parameters. The system automatically stops the line when irregularities are detected, ensuring operator protection.
• Regulatory Compliance – The line complies with all relevant European safety standards and is CE certified, guaranteeing safe operation even under high production intensity.