Automatic Bottle Capping Machine

An automatic bottle capping machine is a specialized piece of equipment designed to securely fasten caps onto bottles, jars, or other containers in an automated manner, ensuring efficient, consistent, and high-speed sealing for various production lines. These machines are critical in industries such as food and beverage, pharmaceuticals, cosmetics, chemicals, and e-liquids, where they prevent leaks, contamination, and spoilage while maintaining product integrity and meeting industry standards.

Automatic Bottle Capping Machine Video

Key Features

1. Construction and Materials:

   • Typically built with durable materials like stainless steel and anodized aluminum for corrosion resistance and sanitary operation.

   • Heavy-duty frames, such as welded C-frames, ensure stability and easy integration with existing conveyor systems.

   • Designed for minimal maintenance with standardized parts to reduce downtime and simplify repairs.

2. Cap Compatibility:

   • Handles a wide variety of cap types, including:

     • Screw caps (plastic or metal, threaded)

     • ROPP caps for tamper-evident seals, common in beverages and pharmaceuticals

3. Automation and Control:

   • Fully automated systems feature PLC controls with touchscreen HMI for easy operation, allowing up to 50 programmable recipes and multiple security levels.

   • Torque control ensures precise application, adjustable from 0.02 Nm to 6.0 Nm for fragile or specialized caps, preventing over-tightening or damage.

   • Some models include servo-driven systems for precise cap placement and digital torque monitoring, reducing misalignment and ensuring consistent seals.

   • Cap sorting and feeding systems, such as vibratory bowls, centrifugal feeders, or elevators, automate cap delivery to the capping head.

4. Speed and Capacity:

   • Capable of capping 20 to 300 bottles per minute, depending on the model and configuration.

   • High-speed rotary cappers are ideal for large-scale production, while inline cappers suit medium to high volumes with easier changeovers.

5. Adjustability and Versatility:

   • Adjustable for various bottle heights and cap sizes, often with tool-less or quick-release changeover mechanisms for rapid setup.

   • Compatible with diverse container materials and shapes.

   • Features like spring-loaded capping discs or independent torque heads provide forgiveness for misalignment and better torque control.

6. Quality Control:

   • Advanced systems include quality checks to verify cap placement and seal integrity, rejecting mis-capped containers.

   • Some models integrate sensors for height inspection or cap detection to ensure compliance with safety and quality standards.

Operational Process

Automatic bottle capping machines typically operate in two phases:

1. Cap Placement:

   • Caps are sorted and oriented in a hopper or feeder and delivered via a chute or pick-and-place mechanism.

   • Pick-off method: Caps are dispensed onto bottles as they pass under a chute, common in inline or rotary cappers.

   • Pick-and-place method: A robotic arm or chuck grabs the cap and places it onto the container, ideal for complex caps like triggers or pumps.

2. Cap Sealing:

   • The capping mechanism applies the necessary torque or pressure to secure the cap:

     • Spindle cappers use spinning discs to rotate screw or lug caps onto bottles, suitable for high-speed lines.

     • Chuck cappers descend over the cap, grip it, and apply precise torque, ideal for fragile or specialty caps.

     • Snap cappers apply downward pressure to secure press-on or snap-on caps, often used for plastic containers.

     • ROPP cappers form threads on aluminum caps during application, providing tamper-evident seals.

   • Servo motors or mechanical clutches ensure consistent torque, with some models allowing real-time torque adjustments via the operator panel.

Types of Automatic Capping Machines

1. Inline Capping Machines:

   • Bottles move linearly along a conveyor, with caps placed and tightened in a continuous process.

   • Ideal for medium to high-volume production with easy changeovers and versatility for screw, lug, or snap caps.

   • Example: ACASI Inline Bottle Capper with Vertical Wheel Cap Feeder.

2. Rotary Capping Machines:

   • Use a starwheel or turret to position bottles under multiple capping heads for high-speed applications.

   • Suited for large-scale production and complex caps like pumps or triggers.

3. ROPP Cappers:

   • Specifically designed for aluminum Roll-On Pilfer-Proof caps, forming threads during application for tamper-evident seals.

   • Common in pharmaceutical and beverage industries.

Benefits

• Efficiency: Automates repetitive tasks, reducing labor costs and increasing throughput.

• Consistency: Precise torque and placement minimize defects and ensure uniform seals.

• Versatility: Handles diverse cap and bottle types, adaptable to various industries.

• Product Safety: Secure seals prevent leaks, contamination, and tampering, extending shelf life.

• Scalability: Modular designs allow integration with filling and labeling lines, supporting production growth.

Applications

• Food and Beverage: Screw caps for water, soda, condiments; lug caps for jars (pickles, jams); crown caps for beer.

• Pharmaceuticals: ROPP and vial cappers for tamper-evident and secure sealing.

• Cosmetics: Pump, trigger, and flip-top caps for shampoos, lotions, and sprays.

• Chemicals and E-liquids: Secure caps for hazardous or sensitive liquids.

Considerations

• Production Needs: High-speed rotary cappers suit large-scale operations, while inline or semi-automatic models are better for smaller runs.

• Cap and Bottle Compatibility: Machines must be configured for specific cap types and bottle materials to avoid deformation or misalignment.

• Maintenance: Regular maintenance and spare parts availability are crucial to minimize downtime.

• Cost: Fully automatic machines are more expensive but offer higher efficiency; semi-automatic options are cost-effective for smaller operations.

Salient Features of Automatic Bottle Capping Machine

• Compact GMP model.

• “No Bottle – No Cap” system.

• “Container Overturn – Machine Stop” mechanism.

• Quick and very easy change over and setting from one size of Container to another by a Single Ratchet.

• Parts coming in contact with the Container or the Aluminum cap or exposed to atmosphere are made out of stainless steel for long life.

• Single motor synchronizes Conveyor, star wheel and Platform Turret and speed can be varied by VFD.

• Star Wheel is equipped with safety clutch for automatic stoppage of machine in case of jamming or overloading.

• Quick and very easy change over and setting from one size of Container to another by a Single Ratchet.

• Digital counter for counting production output.

• Machine construction in Stainless Steel Finish

• Cap Feeder with Variable Speed System for feeding control of caps. (optional)

• Hopper can be completely dismantling for easy cleaning

• Various safety features including Clutch system to avoid Bottle Breakage or Jamming

• IQ/OQ documentation can be provided.

• PLC system with Graphical User Interface can be offered.

• Inbuilt Laminar Air Flow can be offered for sterile class 100 filling.

• Sampling and Rejection system can be provided on demand.

Process Operation of Automatic Bottle Capping Machine

The filled bottles moving on conveyor belt and fed into an in feed star wheel by in-feed worm. While moving in feed star wheel, bottles pick up caps one by one from delivery chute. The descending rotary sealing heads hold bottle’s neck with desired pressure. The sealing is done in a programmed roll-on manner, accurate positioned of the caps is done mechanically by means of a rotating unscramble, to direct the caps correctly into the chute, when the chute is filled up the rotating unscramble drive is disengaged, hence, there is no chance to damage of caps. The sealing roller takes place due to rotating sealing head and transfer movement of sealing & threading rollers due to sealing cam. The sealed bottles are discharged by exist star wheel on conveyors.

Technical Specification of Bottle Capping Machine

* Power voltage can be adjusted as per customer’s domestic power voltage requirements.
* Rights of technical improvements & modification reserved.
* Illustrations & dimensions are shown for information purpose only.