If your current capping machine cannot keep up with production, your company is launching a new bottle format, or you are building a new filling and packaging line, the first question may seem simple:
“What bottle capping machine should I buy?”
The answer depends on much more than production speed.
The right capping machine has to work with your bottle, closure, required torque, cap geometry, production rate, conveyor, cap feeding system, available floor space and future changeovers.
A machine that looks correct on a quotation can still become a production problem if these details are not evaluated before the purchase.
At Filltronic, we help manufacturers, packers and co-packers evaluate these requirements before committing to new capping equipment.
Start With the Bottle and Cap — Not the Machine
Before selecting a capper, define exactly what the machine needs to run.
For every container and closure combination, collect:
- Bottle material
- Bottle dimensions
- Bottle height
- Bottle stability
- Neck finish
- Cap diameter
- Cap height
- Closure type
- Required application torque
- Production speed
- Number of different bottle and cap formats
Actual production samples are extremely valuable.
Two caps that appear similar can behave very differently during sorting, feeding, transfer through the cap chute and application to the bottle.
The same is true for bottles. A tall narrow bottle, flexible HDPE container and short rigid PET bottle may require very different handling even when production speed is identical.
What Type of Bottle Capper Do You Need?
Different applications require different capping methods.
For many continuous bottle packaging lines using threaded screw caps, an inline spindle capper can provide a practical combination of speed, adjustability and continuous operation.
Other applications may require:
- Chuck capping
- Pick-and-place capping
- Retorquing
- Press-on closure application
- Specialized closure handling
The correct technology should be selected from the application requirements rather than simply choosing the machine with the highest advertised speed.
Production Speed Is Only One Part of the Specification
A capper rated for a certain number of bottles per minute does not automatically mean your complete line will operate at that speed.
Actual production depends on factors including:
- Cap presentation
- Bottle stability
- Conveyor speed
- Bottle spacing
- Cap transfer
- Capping head or spindle configuration
- Required torque
- Container flexibility
- Upstream accumulation
- Downstream equipment
- Operator interaction
- Changeover setup
For this reason, the target production rate should be evaluated as part of the complete packaging process.
Cap Feeding Is Part of the Capping System
An automatic capper normally needs a reliable method of supplying correctly oriented caps.
Depending on the closure and application, the system may include equipment such as:
- Cap elevator
- Cascade-style cap feeder
- Centrifugal sorter
- Vibratory feeder
- Cap chute
- Cap escapement
- Pick-and-place mechanism
The cap feeding system should be evaluated with the actual closure whenever possible.
A cap that feeds reliably at low speed may behave differently when production speed increases.
Closure geometry, center of gravity, wall profile, diameter, height and special features can all affect feeding performance.
Do Not Ignore the Conveyor
The conveyor underneath the capper is part of the application.
Important considerations include:
- Conveyor width
- Working height
- Chain type
- Bottle support
- Guide rail adjustment
- Bottle transfer
- Line speed
- Existing upstream and downstream equipment
A new capping machine may fit physically into an existing line while still requiring conveyor modifications for proper bottle control.
That should be identified before the equipment arrives.
Bottle Control Is Critical During Capping
Applying torque to a closure creates a reaction force on the bottle.
If the bottle is not properly controlled, it can rotate, tilt, slip or become unstable during capping.
Inline cappers may use components such as:
- Bottle gripper belts
- Side guides
- Stabilizing rails
- Spacing components
- Timing devices
The correct arrangement depends on the container geometry and capping process.
Poor bottle control can create inconsistent torque even when the capping mechanism itself is functioning correctly.
Think About Changeovers Before Buying the Machine
Many packaging operations run multiple bottle sizes or multiple closures.
Ask how the machine changes from one format to another.
Evaluate:
- Height adjustment
- Spindle or capping-head adjustment
- Gripper belt adjustment
- Guide rail adjustment
- Cap chute changeover
- Cap feeder adjustment
- Tool requirements
- Change parts
- Setup references
- Repeatability
A flexible machine should not only be capable of running several formats. Operators should also be able to reproduce the correct settings reliably.
Ask What Is Included in the Quote
When comparing capping machine proposals, make sure you are comparing the complete application.
A quotation should make clear whether items such as these are included:
- Capper
- Cap feeding system
- Cap elevator
- Cap chute
- Conveyor
- Bottle handling components
- Change parts
- Electrical controls
- Guarding
- Installation
- Startup
- Factory testing
- Documentation
- Freight
A lower equipment price does not necessarily represent a lower installed project cost.
Send Production Samples Before Final Approval
Whenever possible, the equipment supplier should evaluate actual production bottles and caps.
For custom or application-specific equipment, a factory acceptance test using representative final samples can help verify:
- Bottle handling
- Cap feeding
- Closure application
- Torque consistency
- Changeovers
- Production speed
Finding an application problem during testing is much easier than discovering it after the machine has been installed on the production floor.
Should You Repair Your Existing Capper or Buy a New One?
Not every capping problem requires a new machine.
Recurring production problems may come from:
- Worn gripper belts
- Poor bottle control
- Incorrect cap chute geometry
- Worn capping components
- Missing change parts
- Incorrect machine setup
- Cap feeding problems
- Conveyor instability
- Obsolete components
- Poorly documented changeovers
Before replacing the complete machine, it can be useful to determine whether the existing equipment can economically support the current production requirement.
If the machine cannot meet the required bottle range, closure range, production speed or reliability target, replacement may then become the better decision.
Get the Application Defined Before Requesting a Machine
A useful capping machine specification should answer at least these questions:
What bottles are being capped?
What closures are being applied?
What torque is required?
What production rate is required?
How will the caps be automatically supplied?
What conveyor will carry the bottles?
What other equipment must the capper integrate with?
How many future formats must the machine support?
Once these requirements are defined, comparing equipment becomes much easier.
Need Help Selecting a Bottle Capping Machine?
Filltronic helps manufacturers, liquid packers and co-packers evaluate packaging equipment before making a major equipment decision.
If you are considering a new bottle capper, we can review your bottles, caps, production rate, existing conveyor, available space and line requirements and help define what the application actually needs.
We can also help review equipment proposals, identify missing requirements and evaluate how a new capper will integrate with the rest of the packaging line.
You do not need to know every technical specification before contacting us.
Start with:
- Photos of your bottles and caps
- Container and closure dimensions
- Product or application
- Desired production rate
- Current equipment
- Available floor space
- Any equipment quotations you are already considering
Before you buy the machine, define the application.
Contact Filltronic to request a packaging equipment review.