Injection moulding Maximum productivity and efficiency to produce beverage closures

Related Vendors

Netstal Maschinen AG

HASCO Hasenclever GmbH + Co KG

Ramada Acos

At the upcoming NPE event, Netstal will showcase its advanced injection moulding solutions, featuring a state-of-the-art production system from the US-based company Alltrista. This system is acclaimed as the world's most efficient for producing closure systems, demonstrating a production capacity using a 128-cavity mould to manufacture 26 mm water bottle caps, achieving a remarkable cycle time of 1.9 seconds.

Central to Netstal’s exhibit at the NPE is the CAP-Line, designed with a clamping force of 4500 kN and tailored specifically for closure applications. The showcased model, based on Netstal's high-performance Elios platform, includes special equipment features aimed at optimizing the production of beverage closures. Notably, its all-electric clamping unit achieves a dry cycle time of 1.4 seconds, facilitating exceptionally rapid production cycles of under two seconds. Enhancements such as an optimised barrier screw allow for the use of a smaller injection unit, improving plasticising performance and product homogeneity. Netstal also offers customisation options like the Smart Operation control panel and an adaptive system pressure reduction for increased energy efficiency.

A significant innovation at the NPE is the introduction of a system that incorporates a 128-cavity mould, designed by z-moulds and complemented by Intravis peripherals, which matches the systems used by Alltrista. This design not only enables production with reduced cycle times but also minimizes the mould's weight by 25 percent compared to conventional models, offering a compact solution that maximizes output per square meter of production space.

Alltrista, leading the way with this technology, has achieved unprecedented production efficiency, manufacturing over 3.1 billion closures annually with two lines. This achievement not only signifies a leap in production capacity but also represents significant cost savings and a reduction in environmental impact through lower power consumption and a substantial reduction in material use. The CAP-Line 4500, for example, uses approximately 12 percent less electricity than similar machines with only 96 cavities.

Furthermore, the closures produced in this system are lighter by about 25 percent, reducing the material required and thereby lessening the environmental footprint without compromising product quality. This adjustment in the production process results in a savings of over 930,000 kg of resin annually.

Intravis's system partner plays a crucial role in the quality assurance process, with their Capwatcher Q-Line performing comprehensive 360° inspections of the closures at high speeds, checking for over 40 quality criteria with precision. This ensures that only closures meeting the highest standards are delivered to customers, reinforcing Netstal's commitment to excellence in injection moulding technology.

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