From Caps to Corks: How Manufacturers Adapt Packaging Lines for New Products
Very seldom does a company produce one product from Day One and continue to run their business with that same product for years to come. Even if a business produces one product, the packaging will likely vary, from sizes to materials, to closures. One of the most important considerations when introducing a new container or closure is ensuring that the packaging line in place can handle the transition or addition. Selecting the right bottle cappers can help maintain productivity, product integrity, and future growth.
BOTTLE CLOSURE SELECTION
Bottle closures seal a product, and in doing so they protect freshness, preserve quality, help with brand presentation, and provide tamper evidence, among other things. As it relates to packaging equipment, however, the selection of the closure is important because bottle capping machines are generally manufactured to handle a single type of closure, with some exceptions. Selecting the same type of closure for all different products can save money over the long run, by requiring only one capping machine, but for co-packers or other businesses with a wide variety of products, a single machine may not suffice. From screw-on caps for popular drinks and bottled water to corks for distilled spirits and ROPP cappers for wines, even a single industry like the Beverage industry will use different closure types.
ADAPTING TO NEW PRODUCTS
Many new packagers or products may use a screw-on type closure, a cap that is torqued down and sealed using a continuous thread. These closures can be found, as noted above, on bottled waters and other popular beverages, but they may also be used on laundry detergent, household cleaners, motor oil, chemicals, foods, shampoo, and numerous other products across literally all industries. Screw-on closures are what could be termed the default cap in the packaging industry. However, for reasons that number too many to list, other closures may be preferable to the screw-on cap.
Whether a tradition, think corks on wines and other alcohols, or tamper evidence, such as ROPP caps on higher end liquors, some industries lean toward other closures. When packaging products from different traditions or industries, businesses should be able to adapt to new products, even where the closures may be different.
BUILDING A FLEXIBLE PACKAGING LINE
Building a flexible packaging line means setting up a system that can handle all of the needs of the packager. As noted above, most capping machines are manufactured to apply one type of closure, but exceptions do exist. Spindle capping machines, which use matched sets of disks to tighten screw-on type closures, can be built to also apply snap on caps. ROPP cappers, which create threads on bottles and caps during the sealing process for tamper evidence, can be manufactured to allow a packager to swap out the capping heads and apply torque to screw-on closures as well. Other bottle cappers, and bottle corkers, will typically only work with a single closure type. Understanding the range of caps and closures - and bottles - that will be used on a packaging line will allow the bottle cappers to be set up for smooth bottle handling, consistent application of each closure type, and quick and effective changeover, which will lead to minimal disruptions and improved overall performance.
PLANNING FOR FUTURE GROWTH
Businesses grow, expand, introduce new products, and repeat. A business may have the ability to choose only one type of cap or closure, allowing current equipment to adapt to their needs. But for those that package for others, they may never know what the next contract will bring. By planning not only for current needs, but for future growth as well, a packager can include the necessary capping equipment to remain productive. Where multiple capping machines are necessary, integration is key. Being able to roll a capper up to and away from a conveyor system will make the process easier. Combining capping machines where necessary to handle different closure types can be a huge benefit for co-packers and larger packagers.
At Liquid Packaging Solutions, our bottle cappers and bottle corkers are engineered and built to accommodate different production rates, closure shapes, closure sizes, and bottle types. As consumer preferences evolve, packaging styles change, and LPS can help you adapt and find the ideal solution for your own packaging process, whether that be a single cap type or multiple different closures.