Sealing the Deal
by Lynn Petrak
Filling and capping technology sends product on its way
faster, cleaner and more efficiently.
Like a superhero, today's manufacturing
suppliers are trying to do things better and faster. While they may not be
able to help processors leap across production steps in a single bound or
fly their products from one point to another, they are making headway in
helping dairy customers boost throughput, increase efficiency and become
Improvements are being made across the production
chain, including filling and capping technology, as dairies and suppliers
together make adjustments and invest in upgrades to accommodate new
products and operations. Filling and capping equipment and materials can be
considered the last bridge between products and packaging, used to fill and
seal many types of products in an increasing variety of package styles.
Capping and filling suppliers share the view that
their equipment and materials must change with the times. "Customers
want everything now, and without being too cliché, they really want
their expectations exceeded," reports Peter Perkins, national sales
manager for Osgood Industries, Oldsmar, Fla. "They want the latest
technology, 100 percent efficiency of operation, at the best price with
above-average service response time, and they want it now."
Nick Manley, media and marketing manager for Autoprod
Inc., Clearwater, Fla., agrees equipment innovation often stems from dairy
customer demand for getting more out of less. "Many innovations have
been developed from the needs of our customers, which include higher
speeds, higher efficiencies and more flexibility," he says.
The need for speed, specifically, has been a driver of
filling and capping technology in recent years. "On the dairy side,
especially with all the consolidation going on, the big dairies want a
couple of plants to do all the production," says Rich Szyperski,
manager of technical services for Cedar Rapids, Iowa-based Evergreen
Packaging, a division of International Paper. "We are getting asked
about machines with requirements of 600, 700 or 800 bottles a
Different package styles naturally affect filling and
capping, too, says Szyperski. "A lot of changes are more along the
lines of new product development or new package formats. With blow-molding
capability and bottle-making capability today, there are a lot of different
companies wanting different shapes of bottles to be unique," he says.
Such an interest in being distinctive is also leading
to more customization. "Other than meeting our long-term customers as
well as new customers, we receive requests asking us if we would consider
supplying fillers with certain features," says Otis Cobb, president
and general manager of Milwaukee-based Federal Mfg. Co. "We have
noticed that these people who are making special requests are usually the
leaders in the industry. We pay special attention to the requests of these
people and make every effort to accommodate their ideas."
Fill 'Em Up
Filling machinery is an example of how technology is
keeping pace with demand. Lately, many equipment makers have unveiled new
models designed for broad dairy product applications.
One particularly active area of development has
centered on fillers that work with extended shelf-life (ESL) products. The
development team at Federal, which has sold dairy fillers for more than 40
years, found the demand for flavored milk bottles ultimately was linked
with ESL capability. "There started to be an increased interest for
filling and capping systems to extend shelf life," reports Cobb,
adding that the company developed additional support equipment for its 10
ESL lines for fresh milk and juice in recent years and was ready to move to
the next stage. In October, Federal rolled out a 30-valve ESL net-weight
filler that is now being prepared with the company's new bottle
sanitizing system and all support equipment necessary for an ESL filling
and capping line.
Cobb says the ESL system was built with several
features that help ensure efficient and reliable operation, including the
latest load cell and communication technology. "The system primarily
fills by weight using load cells. However, during the filling cycles, the
system gathers data on the time required to fill the bottle at each
station," explains Cobb. "Should some problem occur with any
one of the load cells, that particular station can be switched to time fill
using the historical data that has been collected."
Evergreen Packaging Equipment has also seen interest
in ESL-capable models increase. "It seems to be pretty wide open
there," says Szyperski. "A lot of people are asking for
different configurations and different levels of technology, from basic
cleanup to as close to aseptic as you can get it without calling it
Evergreen's latest entry in this area is its
ESL-60 Gable Top Filler for fresh milk and juice, which forms, fills and
seals paper gabletop cartons at speeds up to 6,000 cartons per hour in
sizes ranging from 6 ounces to 38 ounces. ESL features include enclosures,
HEPA, auto sanitization, self-contained clean-in-place (CIP) features,
low-level H202 carton sanitization with ultraviolet light and
self-contained chemical sanitation.
Evergreen offers other equipment and supporting
features designed to meet ESL requirements as well, including ESL rotary
bottle filling equipment using volumetric electronic filling systems (EFS).
The company's Unibloc fillers offer rinsing, filling and capping
capability and can be adapted to a variety of bottle sanitation needs,
while its Monobloc fillers allow for filling and capping. "For
rinsing, filling, and capping, we've been able to put them all
together utilizing one single-drive motor," explains Szyperski.
"It's integrated equipment that is run off the same motor under
With more demand for CIP features, manufacturers are
working to enhance other sanitation aspects of their filling systems. Last
fall, Evergreen launched its advanced hygiene filler, the BFAH-30. The
model includes several new features, such as a belt drive, externally
demountable fill valves, auto sanitization, HEPA, enclosures and an
optional automated CIP system, and is equipped to fill up to 100 gallons,
150 half gallons and 180 quarts, pints or half pints per minute.
"It's taking jug filling to the next level. We're putting
clean features on standard jug fillers to add security and to keep the
outside environment from getting inside the bottle," says Szyperski.
The fact that the Evergreen's BFAH-30 uses an
electronic control reflects another trend toward more powerful machines.
Perkins says that Osgood has also shifted some emphasis to this area.
"The biggest change for Osgood over the past year is the increasing
use of servos to operate our systems. We have a great deal of experience
now with these," he says. "The shortcomings have been addressed
and we have isolated a brand that is capable of meeting the rigorous
environments these systems operate within."
One of Osgood's latest introductions includes
full servo capability. "The most significant upgrade we made in 2003
was for our Model RF-S-100 rotary 56 and 64-ounce ounce ice cream filler.
The full servo operation of this system now allows us to achieve operating
speeds of 80 containers per minute while maintaining ever tighter weight
controls through the patented use of a servo to actually measure resistance
and correlate that to a specific weight of a filled package,"
explains Perkins, adding the rotary filler was designed for straight-walled
Other recent filling equipment innovations address the
ongoing demand from dairy customers for accuracy. Autoprod recently
upgraded several filling systems with the latest technology to improve the
fill accuracy of its systems. "The upgrades have made the filling
systems approximately three times more accurate than the previous
version," says Manley, adding that efficiency has been boosted as
While suppliers are regularly working on new and
improved fillers, they are aware that some dairies are using older models
that must be maintained or replaced with different parts. "Federal
has fillers that were manufactured in 1952 that are still in
operation," says Cobb. "Improvements and new developments for
our current models are normally designed so that they may be adapted to
most older fillers. Older filers may be upgraded to fill different types
and sizes of bottles as well as converting capping systems to handle a wide
variety of different closures."
Other equipment and material innovations are taking
place on the capping side of operations. Some manufacturers that supply
filling machines also provide container closing lines, such as Osgood,
Autoprod and Evergreen, among others. "We offer capping equipment for
flat caps, sports caps, press-on caps and screw-on caps. Any capping you
can think of, we have a solution available," says Szyperski, adding
that Evergreen is also set up to handle heat-sealing for aluminum foil caps
commonly used for ESL beverages.
As with filling equipment, capping machines are now
geared to be faster, more powerful and designed for superior sanitation.
Lebanon, N.H.-based packaging company NJM/CLI, for example, has developed a
new line of heavy-duty stainless steel rotary cappers in a variety of
multiple head configurations. The RotaCap Capper can handle up to 800
containers a minute in sizes ranging from 30 ml to 5 liters, and is run by
a PLC-controlled variable speed operation.
San Jose, Calif.-based Portola Packaging, which
supplies both caps and closures and capping equipment, also pursues the
latest technology for its products and services. In addition to its
conveyance systems, application systems, feeding systems, assembly systems,
cap labeling systems and foil and foam insertion machines, the company also
redesigns support features for various systems. "We are working with
a big customer right now to design new equipment with a floor hopper, to
dump a case of caps into a floor hopper rather than having someone go up a
ladder to do it," explains John Borrelli, director of sales for
Portola's dairy division in New Castle, Pa. "This saves
time, allows for more efficiency and is also a safety feature, because you
don't have people going up and down a ladder."
Capping systems are increasingly designed to
accommodate a greater variety of caps and closures that are used by dairies
today, as well as a more diverse array of bottles. International Plastics
& Equipment Corp. (IPEC), New Castle, Pa., offers 28 mm and 26.7 mm
sport and flat closures intended for the new generation of "light
finish" bottles currently being used in some non-carbonated markets,
including by some dairies. IPEC's
38 mm snap-on/screw-off,
snap-on/snap-off, and screw-on/screw-off flat closures also can be used for
many types of resins, from HDPE to PET.
Meanwhile, many suppliers have been busy creating
advanced caps, some with multiple pieces, designed for consumer
convenience, safety and security as well as for greater protection against
leakage. Portola recently rolled out a new tamper-evident pull ring with an
easy-open closure, the ASC III, along with a new Alpha 5, an advanced
snap-screw closure. According to Borrelli, the ASC III is similar to what
the company supplies to orange juice makers for their cartons.
"We've incorporated that with a new sealing technique,"
he explains. "It's a culmination of a couple of things. The
molded-in membrane creates a much better seal than anything on the market
today and the equipment can still run through standard feeding equipment,
with a press-on plate to press the cap onto the bottle. It's very
complementary to capping equipment."
Indianapolis-based Alcoa Closure Systems International
(CSI) also has carried over technology from juice to dairy. Alcoa
CSI's Seal-MAX™ closure was designed to prevent leaks and
provide tamper evidence for packages ranging from single-serve bottles to
gallon-sized high density polypropylene (HDPE) containers. Used for screw
tops, the cap features Alcoa's Extra-Lok™ tamper evident band
for a two-piece closure that is easily separated by the end user.
Diversifying Their Portfolio
As recent mergers and acquisitions within both the
equipment and dairy industries have demonstrated, operations are growing
more centralized across the board. Integration has also impacted companies
that supply filling and capping technology, as manufacturers recognize the
need to diversify their own offerings and perhaps even expand into other
Last year, for example, Osgood introduced a new form-fill-seal
thermoforming system. "Osgood decided to get into the thermoforming business
due to ever-increasing amount of flexible packaging in the marketplace," says
Perkins, "and also to capture additional opportunities that we couldn't pursue
Lynn Petrak is a freelance journalist based in the Chicago
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