It’s a pretty safe bet that most packers who cap bottles by hand to prepare them for sale don’t look forward to the process. Not only can it be tedious and time-consuming when the numbers are large enough, it can pose a hazard to twisting, pushing, and straining in the form of repetitive motion injuries. Also, some closures are simply not conducive to manual sealing, such as ROPP caps that require knives to screw in the caps when applied. At some point, capping machinery can truly become a necessity for packers, and the benefits of such equipment will remain largely the same, whether using semi-automatic equipment or fully automated bottle cappers. The use of capping machinery also has other benefits, some of which are detailed below.
1. Consistency and reliability
Whether semi-automatic or automatic capping equipment is used, one of the biggest benefits is that bottles and other containers will be sealed consistently with each cycle. In addition to the fact that human hands simply do not tighten all caps in the same way, the long time spent sealing bottles can lead to fatigue and, if we’re honest, boredom, leading to inconsistent and unreliable capping. Automated capping machines are built to cap each and every container in the same way, either 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 tightening, pushing, or sealing will be done by the machine itself. Automatic machines will only require an operator to perform the initial setup, as cap delivery systems will be used to present closures to bottles.
2. Limiting speed
Given enough time, or divided into enough shifts, manual capping can be a fairly consistent and reliable method of preparing product for the shelf. However, as the numbers increase, taking the time to avoid fatigue, boredom, and injury would ultimately lead to an ineffective capping process. Bottle capping machines will generally increase speed over manual capping, and automatic machinery will reach speeds of up to 100 bottles per minute or more. Almost all packers looking for an automatic capping machine will expect higher production, but there are some exceptions to this rule. As noted above, capping machines can bring consistency and reliability to the process, and some manual and tabletop capping machines will be used for these purposes, even without a significant increase in speed. However, most of the time, the speed with which the sealing can be performed will be one of the main benefits of using capping machinery.
3. Simple operation
Although things can’t be much simpler than screwing on a lid or pushing in a cork, good capping machines are designed to make things easier for the operator. Semi-automatic equipment will generally require the operator to put the cap on the bottles and slide the combination into place to allow the machine to seal. Automatic machinery will require initial setup and a bottle-to-bottle switch, but once in operation it generally only requires the operator to make sure the closures are available to the machine from time to time. The best capping machines will require no tools for installation whenever possible, relying on cranks and knobs to make adjustments. While unique containers and closures may lead to some exceptions to tool-free setup and adjustment, the ability for almost anyone to operate capping machinery is a third benefit for packers.
4. Versatility
Very rarely will a company pack a single product in a single container, using only one type of cap 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 they are flat caps, flip caps or even trigger sprayers, a single screw capper can be built to handle a range of screw caps. Some machines can even be combined to handle different types of closures, such as a spindle and a pressure capper. This machine can tighten continuous screw 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 who specialize in a specific type of machine, be it a liquid filler, capper, 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. Meaningful processes such as filling or labeling may already be automated when a packer searches for a capping machine. The benefit 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 all companies.
The benefits of adding automation to the limiting process will vary from project to project, as will the amount of automatic adding, but the benefits listed above will often be the motivating factors for change. An analysis of containers, closures, product demand, space and budget for any project should always be done when looking for the best capping solution, which can add efficiency, speed, reliability and much more to the packaging process as a whole.
