SGP-200 Automatic In-Line Capper

Automatic Capping Machine: The Ultimate FAQ Guide

In this guide, you will learn everything you need to know about automatic capping machine.

From parts, working principle, features to customization options, you will find all information about capping machines right here.

Keep reading to learn more.

What is Capping?

Capping is the process of placing a seal, cover, lid, or cap on bottles and containers.

Automatic capping machine

An automatic capping machine is a piece of equipment that will automatically place seals over containers and bottles.

This process usually happens after the filling process to protect the contents inside the containers and bottles from spilling and contamination.

An automatic capping machine will perform this task in a fast and reliable manner on different types of containers.

How does a Semi-automatic Capping Machine compare to a Manual Capping Machine?

Capping machines

A semi-automatic capping machine is costly than a manual capping machine.

The operator in a semi-automatic capping machine will place caps on bottles before packaging.

The operator in a manual capping machine will place the caps on bottles, then place the capper above the cap.

A semi-automatic capping machine is much faster than a manual capping machine.

To increase the speed of a manual capping machine, you need more machines and operators.

A manual capping machine is suitable for small scale industries.

A semi-automatic capping machine is suitable for medium and small scale industries.

Manual capping machines are small in size than semi-automatic capping machines.

A semi-automatic capping machine can come in various designs that a manual capping machine.

What are the Applications of an Automatic Capping Machine?

Many industries use an automatic capping machine for a reliable capping process.

Some of these industries include:

Beverage Industries

Examples include:

1. Can beer
2. Soda
3. Water
4. Fruit juices
5. Carbonated beverages
6. Energy drinks
7. Wines
8. Spirits
9. Low-calorie drinks
10. Coffee
11. Carbonated water
12. Isotonic drinks
13. Bitters
14. Distillates

Food Industries

Examples include:

1. Preservatives
2. Vinegar
3. Sauce
4. Tuna
5. Milk
6. Honey
7. Marmalade
8. Nutrition powder
9. Yogurt
10. Oils from olives and various seeds

Cosmetic Industries

Examples include:

1. Lotions
2. Deodorants
3. Shower gels
4. Soaps
5. Makeups
6. Perfumes

Pharmaceutical Industries

Examples include:

1. Tablets
2. Syrups
3. Capsules
4. Care products

Chemical Industries

Examples include:

1. Insecticides
2. Fertilizers
3. Air fresheners
4. Paints
5. Candles
6. Glue
7. Cleaning liquids
8. Farm chemicals
9. Detergents
10. Fungicides
11. Weedkillers
12. Ink
13. Lube oils

What are the Features of an Automatic Capping Machine?

An automatic capping machine has many advantageous features.

These features, however, differ from one automatic capping machine to the other.

Some of these features include:

· Frame Unit

The body of an automatic capping machine is from S304 stainless steel together with hard-anodized aluminum.

Its frame unit also has a liquid outlet that allows an easy cleaning process after the capping process.

The stainless steel meets all safety and hygiene standards.

· Bottle-Feeding and Conveyor Unit

An industrial plastic wheel unit allows the bottles to move smoothly without scratching the surface of bottles.

The machine will automatically stop if it notices jamming of bottles at the exit of the conveyor.

Besides, the machine automatically resumes once you clear the jamming.

It also has a motor overload prevention that will inhibit bad operation, which will cause damage to motors.

· Monitoring Unit

The monitoring unit will keep all records of a faulty operation.

PLC I/O monitoring module will monitor the PLC input and output.

This will ensure an efficient troubleshooting process.

The monitoring unit has management and operational functions.

· Interactive Interface

A programmable logic controller [PLC] and human-machine interface [HMI] allows for easy and accurate setups and operation.

A memory unit stores operation parameters for a fast set up.

· Capper Unit

The capper unit has a quick release unit the allows for easy changeovers.

Besides, the height level of the capping deck is easily adjustable for various production needs.

A high tech servo module has adjustable torque and speed turn values.

These guarantees adequate tightness and that the cap has no scratches.

An accurate cap feeding chute allows for smooth cap feeding with no jamming.

A cap stabilization unit allows for accurate positioning of caps on the mouth of the bottles.

Servo wheel units ensure accurate positioning of bottles.

What are the Technical Specifications of an Automatic Capping Machine?

Just like the features of an automatic capping machine, the technical specifications also differ from one machine to the other.

At face value, the technical specifications will indicate the capabilities and physical attributes of the automatic capping machine.

Some of the technical specifications of an automatic capping machine include:

• The machine needs a supply voltage of 220 or 380 VAC, 50 or 60 Hz, and single or 3 Phase.
• The average power consumption is 1.5 KW.
• The air requirement is between 90 and 125 PSI.
• The average weight can be around 650 kg.
• The air pressure it requires is about 4 to 6 kg.
• The capsize it can handle is between 10 mm and 130 mm.
• The torque range is between 0 and 250-inch pounds.
• The machine can handle a minimum bottle of 0.5 inches and a maximum bottle width of 12 inches.

What are some of the Automatic Capping Machines that are available in the Market?

 Section of automatic capping machine

There are many automatic capping machines available in the market today with different capabilities.

More technological advancements are making these machines more reliable and efficient.

The type of cap you need to use will influence the automatic capping machine you will purchase.

Some of the automatic capping machines include:

Automatic Chuck Capping Machine

An automatic chuck capping machine will automatically place and torque caps.

It can come with a cap sorter which will sort the caps.

A mechanical swing arm will individually pick and move the caps to the chuck head.

The containers remain stable with help of a pneumatic bottle gripping assembly.

This machine is specific to bottles and caps hence its high price.

It can handle small bottles that may tumble over in the production line.

Automatic Snap Capping Machine

An automatic snap capping machine will apply a press on the head or press belt while sealing containers.

As bottles move along the conveyor belt, the head or belt will apply pressure on the caps to close them.

An automatic snap capping machine can cap a wide array of caps, containers of different shapes and sizes.

This machine will use a delivery system like an elevator and chute to pass the closures to the containers before sealing.

Automatic Benchtop Capping Machine

An automatic benchtop capping machine will eliminate the strain and fatigue you associate with hand capping.

The machine has good ergonomics, comfort, and is easy to use.

Air cylinders will press down on the caps to the bottles and containers.

Automatic Vertical Cap Placing Machine

An automatic vertical cap placing machine will vertically place a large cap in a stationary container.

This machine is suitable for cap sizes above 80 mm.

This is because such large caps will not seat properly on the average spindle and inline capping machines.

Also, this machine can achieve an economical advantage when you use it with an inline cap tightening machine.

Automatic Cap Tightening Machine

An automatic cap tightening machine will tighten caps at speeds of up to 105 caps per minute.

The machine is flexible and can use a single capping head or up to four capping heads.

Having many capping heads will increase the productivity and capping speed of the machine.

This machine can tighten cap sizes ranging from 10 mm to 130 mm.

Automatic Inline Capping Machine

An automatic inline capping machine can serve different purposes.

The machine is very flexible and can handle a wide array of containers and caps.

This can all happen without changing the parts.

An automatic inline capping machine can come with 4, 6, or 8 spindles.

This machine can operate at high speeds and achieve a capping rate of 200 caps per minute.

It also has independent spring capping discs that achieve better torque.

What are some of the Cap Types Available?

There are different types of caps available, and this will influence the type of capping machine you choose.

Here are the various types of caps:

 Automatic capping machine

· Child-resistant Caps

A child-resistant cap has a mechanism that makes it difficult for children to open.

Most pharmaceutical industries use this type of cap.

· Tear-off Caps

A tear-off cap is simply torn off from the container.

· Tamper-proof Seals

A tamper-proof seal will change its color once you remove it.

The seal can fall off or tear making it easy to see the break.

· Crimp Flutes

An automatic capping machine will press a crimp flute on the flaring skirt of a metal disk.

This disk has a strong internal disk that will form the actual seal.

· Cork Caps

A cork cap will use the lightweight elastic external part of the cork oak.

Cork caps are suitable for capping bottles.

· Screw Caps

A screw cap will secure a container by using threads on the cap.

· Press-on Caps

A press-on cap is also known as a snap-fit cap.

A press-on cap will hold on a container by use of beads or undercuts and not threads.

· Crown Caps

Crown caps are common in beverage industries to seal bottles.

Aluminum makes up the crown cap.

What is Capping Rate?

Capping rate is the number of caps a capping machine can achieve per unit of time.

What are you to Consider when Choosing a Capping Machine?

There are several factors to consider while choosing a capping machine.

Here are some of the factors worth considering:

· Type of Caps

It is important to choose a capping machine that is suitable for the caps you have.

Screw caps are popular for capping plastic bottles.

Spindle capping machines and chuck capping machines are suitable for screw caps.

The capping machinery you select should match the cap you are using.

·Size of the Caps

Bottle cap options

Caps come in various sizes depending on the bottle you are capping.

For instance, a spindle capping machine is suitable for screw caps as it can cap a wide array of bottle and cap sizes.

It is also easy to use and perform a changeover of parts to fit the cap and bottles.

A chuck capper is suitable if you are to cap vials and tubes.

A capping machine that can handle a variety of caps and bottles is more economical and time-saving.

· Production Capacity

The production capacity you need to achieve will influence the level of automation you need.

For instance, a semi-automatic capping machine is suitable to achieve low and medium production rates.

A fully automatic capping machine is suitable to achieve large production capacities.

· Future Expansions

The capping machine needs to handle upgrades in the future to accommodate changes in production.

For instance, some semi-automatic capping machines can accommodate an automatic frame.

This is important since you can use human labor when the production capacity is low.

When you anticipate an increase in production, you can upgrade it to a fully automatic system easily.

Adding a capping delivery system and a control panel will change a semi-automatic capping machine to a fully automatic one.

Considering the future growth will enable you to choose the best capping machine.

· Integration with other Machines

Using a capping machine with other production machines can level up your production levels.

For instance, you can integrate automatic fillers, labelers, rinsers, packaging machines, etc.

If you anticipate going fully automatic, you can consider if the capping machine you are using can fit seamlessly with other machines.

· Floor Capacity

The size of the production plant will determine the size of the machine you can purchase.

Large floor space will allow you to purchase a large capping machine with a high production capacity.

· Level of Automation

The level of automation will influence your production capacity.

Fully automatic capping machines will enable you to achieve a high production capacity than a manual capping machine.

· Budget

The budget you have will influence the kind of capping machine you can purchase.

Fully automatic capping machines will cost more but will save you a lot in the long run.

This is because you will not have recurring costs like human labor as the machine will operate independently.

What are the Components of an Automatic Capping Machine?

Several components make up an automatic capping machine.

Some of these components include:

 Capping system

· Conveyor System

The conveyor system will assist in moving the bottles and containers from one part of the machine to the other.

This part will also guard the containers in position during the capping process.

· Gripper

The gripper will prevent the bottles and containers from rotating when you are applying a cap.

· Chuck or Quill

The chuck applies force to the cap to make it rotate.

Also, the chuck will hold the cap and turn it to cap the bottle or containers.

· Chute

The chute will hold the caps in position during the capping process.

It will place caps on the containers before they undergo capping.

· Control Panel

A control panel is a central place where the operator can monitor the capping process.

The operator can also input commands via the dials and touch screen.

· Cap Sorter

The cap sorter will align the random caps in order as they exit the hopper.

Also, the cap sorter can determine the capping speed of the machine.

· Hopper

The hopper will hold the caps that will seal the bottles and containers.

The size of the hopper depends on the size of the caps.

·  Motors, gear boxes, and drives

These components will provide the driving force to other components of the machine.

Besides, these parts can assist in controlling the speed of the capping process.

· Pulleys

The pulleys will connect the conveyor belt and gears.

Pulleys come in various designs and will assist in moving various parts of the automatic capping machine.

· Shafts and Sprockets

The shaft and sprockets will help in relaying rotary motion to the shafts.

It helps to drive other parts of the automatic capping machine during the capping process.

· Air Cylinders

Air cylinders will provide the force that will assist in closing snaps and twisting caps.

This system will also hold back the caps in the automatic capping machine.

How does an Automatic Capping Machine Operate?

An automatic capping machine works by placing a cap on a container or bottle that has contents.

Here are the basic steps on how an automatic capping machine operates:

· Feeding the Caps

The first step involves filling the hopper with the caps that suit the containers.

Also, the cap sorter will align the random caps in an orderly fashion as they exit the hopper

· Feeding the Automatic Capping Machine with Containers

The operator will feed containers that have contents to the capping station via the conveyor belt.

· Placing and Sealing the Caps on Lids

The gripper will hold the bottles steadily while the chute holds the caps in position during the capping process.

The chute will provide caps to the bottles and containers.

After this, the spinning discs will apply force to the cap to make it rotate and seal the containers.

· End of Capping

After the capping process, the containers will move to the end of the capping line.

The containers and bottles are now ready for packaging and delivery.

How do you Troubleshoot an Automatic Capping Machine?

An automatic capping machine can experience some faults during the capping process.

Missing caps are one of the common problems that an automatic capping machine may experience.

A missing cap may mean no cap, cross threaded cap, crooked cap, or other faulty cap placements.

The cap delivery unit and the capping machine must be in line with each other.

Confirm the position of the delivery unit if you notice missing caps.

A strong vibration or a bump can cause this misalignment to happen.

Simply realigning these components can fit the issue of missing caps.

Another issue can be with the conveyor and the speed of the component.

For instance, the gripper that holds the bottles and the conveyor belt have to run at the same speed.

Adjust and alight the speed of the conveyor and the components to sort out this issue.

What Quality Standards should an Automatic Capping Machine Conform to?

An automatic capping machine has to conform to quality standards for health and safety reasons.

Some of these quality standards include:

• The European Union [CE Marking]
• International Organization for Standardization [ISO]
• Good Manufacturing Practices [GMP]
• Food and Drug Administration [FDA]

What Types of Bottles does an Automatic Capping Machine Support?

An automatic capping machine can support a wide array of bottle types.

Examples of these bottles include:

• Polypropylene [PP] bottle
• Polyethylene terephthalate [PET] bottle
• Polyvinyl chloride [PVC] bottle
• Low-density polyethylene [LDPE] bottle
• High-Density Poly Ethylene [HDPE] bottle
• Glass bottle

What are the Components you can Customize on an Automatic Capping Machine?

There are possibilities of customizing an automatic capping machine.

Some of the components you can customize include:

· Whole Equipment

This involves manufacturing the whole equipment as per your specific needs.

· Production Speed

It is possible to customize the production speed to meet your production needs.

· Size of the Machine

Choose the size of the machine so that it fits your production plant.

· Electrical Parts

Select specific brands of the electrical components to be in your automatic capping machine.

· Raw Materials for the Equipment

Select the raw material that makes up the automatic capping machine.

This can be #304 or #306 stainless steel.

What is the Customization Process for Automatic Capping Machine?

The customization process involves:

• Creating the drawing of the machine
• Fine-tuning the design of the machine
• Crafting the machine
• Conducting a performance test

How can an Automatic Capping Machine Benefit your Business?

The benefits include:

• Increasing your production capacity.
• Increasing sales and profits.
• Meeting your client’s needs.
• Possibility of integrating with other machines.
• Decreasing your overall recurring costs.

What Factors Determine the Price of Automatic Capping Machine?

These factors include:

• Raw material that makes up the machine
• Manufacturer
• Production capacity

What is the Cost of an Automatic Capping Machine?

An automatic capping machine can cost you between 1500 US dollars to 50000 US dollars.

How should you Maintain Automatic Capping Machine?

Some of the steps of maintaining an automatic capping machine include:

• Replace or repair all broken and worn out parts like chucks and belts.
• Lubricate moving parts to minimize corrosion.
• Replace faulty electrical components to avoid fire hazards.
• Regularly inspect all components to ensure they are in good working condition.

What Quality Control Process does Automatic Capping Machine Pass?

Quality control processes include:

• Selection of the raw materials that make up the body.
• Inspecting the parts of the machine.
• Machine assembly.
• Final inspection.
• No-load run test.
• Final polishing of the machine.
• 

 Automatic capping machine

What support equipment can you integrate with an automatic capping machine?

The support equipment you can integrate include:

• Filling machine
• Labeling machine
• Packaging machine

Depending on your specific needs, SaintyCo offers a range of automatic capping machines.

Contact us today for all your automatic capping machine requirements.