06/16/2009

Schuler’s necking machine gives new design freedom for spray and beverage cans

The market for metal packaging such as beverage cans, spray cans or containers for the food industry is very large. According to trade association APEAL, around eleven billion steel aerosol cans are produced every year and almost six billion cans are made from aluminum.  The figures for beverage cans are even more impressive: experts estimate that 230 billion aluminum cans are produced every year.

Hinterkopf and Schuler integrate new necking machine for creative new can shapes

Hinterkopf, a turnkey supplier of metal can manufacturing systems, now offers equipment available with high-precision necking machines manufactured by Schuler, using advanced technology to meet the demands of the aerosol and beverage can markets.  These integrated systems have the ability to form new attractive shapes and designs which appeal to consumers -- while achieving better efficiency and material savings.

Spray and beverage cans are produced on complex machines which combine a number of technologies.  Many processing stages are integrated to produce these cans or tubes – from aluminum coil or circular aluminum blanks to the finished packaging product.  After they leave the production line, the cans only need to be filled and sealed before making their way to store shelves.

Production bottleneck eliminated, with completely new possibilities for design

“The bottleneck in the production of modern aerosol cans is the so-called necking machine,” explains Alexander Hinterkopf, CEO of Hinterkopf. “With previously available models, it was impossible to produce specially formed or embossed packaging.  But the body shaping and embossing of the can is high on the list of customer wishes.”

If at all, these forming operations for necking could only be performed on complicated and often error-prone double or triple machines.  Since 2007, the experts at Hinterkopf and Schuler have collaborated on the development of a new necking machine, and are pleased to announce these systems are now field proven and creating more complex shapes with high and efficient productivity.

“We have focused on increased output, greater flexibility and enhanced quality,” stresses Markus Röver, head of Schuler’s High Speed division. He adds: “To achieve this, our necking machine concept takes a holistic approach to the critical elements of the equipment: the press body, slide guiding and drive. By separating the press body from the drive forces and making the slide guiding play-free, we can achieve exact part positioning and a precise forming movement. The result is maximum output with high quality.

The new machine was recently unveiled as the N40V. The name refers to the 40 work stations which enable the addition of forming tools, such as cutting and rolling stations. The stroke can be adjusted in 1 inch (25 mm) increments up to a maximum length of 12.75 inches (325 mm) to enable body shaping. This maximum stroke length means that necking up to 12,6 inches (320 mm) on cylinders of up to 12.5 inches (320 mm) long can be formed. The machine’s maximum output varies according to the stroke length. Up to 240 cans per minute can be produced with a short stroke of 6 inches (150 mm) and 150 cans per minute with a long stroke of 10.5 inches (275 mm).

Suppliers aligned for top quality and machine availability, with reliable service

Schuler supplies the complete necking machine with all components, i.e. drive, slide guiding and large components to Hinterkopf.  As the turnkey supplier, Hinterkopf is responsible for the final assembly of the electrical system and equipping with loading and unloading lines, washing, drying, decoration, storage, forming and sizing tools, as well as the control system, and for launching production at the customer’s facility.

Schuler manufactures all cast and welded parts for the machines itself. This also guarantees short delivery times should customers require replacement parts.  Schuler also offers prompt on-site service support. Its network of global service centers ensures fast response times to maintain high machine availability. Schuler’s head office in Göppingen is just three miles (five kilometers) away from Hinterkopf’s headquarters in Eislingen. Customers and potential clients can therefore easily inspect the complete line in operation before turnkey delivery.

Schuler’s technology focused for the packaging industry

Beyond the necking machine, Schuler’s XS range which launched in 2006 represents a new generation of impact extrusion presses. With press forces of 170 to 450 US tons (150 to 400 metric tons), they are important components for Hinterkopf’s forming operations. A total of twelve of these cutting-edge lines are installed around the world so far.

In addition to lines for aerosol can production and cupping presses for the manufacture of beverage cans,  Schuler’s Swiss subsidiary Beutler Nova also sells press systems for packaging.   With its PAL 400 and PAZ 630 special presses, Beutler Nova offers high-performance system solutions for forming aluminum and tinplate which are exactly tailored to the “form, fill and seal” process chain.

Applications include innovative capsule systems used for coffee and other hot beverages or light metal containers for food and pet meals. Several Beutler presses and a lid blanking machine supplied by Berhalter AG are featured at the unique Swiss Competence and Training Center of toolmaker Leuthold Mechanik AG in Samstagern/Switzerland. Packaging manufacturers can configure, test and coordinate complete production lines at the center.

“We aim to steadily expand our range of products for the packaging industry,” explains Markus Röver. The complexity of the processes means that highly specific know-how is required – from development to production. This is exactly where Markus Röver sees Schuler’s key strengths. Thanks also to their many years of close cooperation with the specialist supplier Hinterkopf, the metalforming experts are ideally placed to utilize their expertise for the benefit of the packaging industry.

Hinterkopf, founded in 1962 and based in Eislingen, Germany is a global leader in machines and installations for the production and decoration of cylindrical hollow plastic and metal packaging. Their lines boast high output and quality, as well as a modular concept which offers users a high degree of flexibility.

Schuler is an equipment systems partner for the packaging industry, supplying cupping presses to produce two-part beverage cans, and now a new generation of impact extrusion presses.  Based in Göppingen, Germany, the press manufacturer has installed some 2,500 equipment lines around the world since the 1960s, including 800 impact extrusion presses.