05/10/2011

Aerosol can production goes vertical – sustainability with increased efficiency

Schuler today unveiled a new machine concept for the production of aerosol cans at the “Metpack” fair in Essen, Germany. The so-called ICON V-Drive is a vertical machine for the forming of can bodies (bodymaker) which boasts compact dimensions, extremely low material consumption and the possibility to process recycled materials.

With rising raw material and energy costs, the issue of sustainability is becoming increasingly important for the manufacturing process. Schuler has responded to the challenge with its ICON V-Drive vertical bodymaker.

In contrast to conventional impact extrusion methods currently used to produce aluminum cans, manufacturers can also form higher-strength alloys with the vertical drawn and wall-ironed (DWI) process used by the Bodymaker. This in turn enables the production of thinner walled cans, for example, thus saving material. Moreover, even 100% recycled aluminum alloys or tin plate can be used. As the punch moves vertically from top to bottom, no lateral forces can affect it. This prevents any possible deflection and bending vibration. As a result, the repeat accuracy of the process is greatly improved.

Schuler has also ensured efficiency with its choice of drive. By using servo technology, there are no mechanical transmission elements – such as clutch or brake – thus minimizing any energetic losses.

Disc-to-can – cupping press and bodymaker in one machine

A further technical highlight of the ICON V-Drive is the integration of cupping and forming in one machine. Depending on their particular production equipment, this means can manufacturers no longer need to carry out the blanking and cupping processes. Instead, they can manufacture cans straight from the disc. This machine concept not only simplifies the production process, but also does away with the former problem of waste logistics. Users simply have to collect the raw can trimmings and add them to the recycling process. All in all, Schuler expects the new machine to reduce material consumption by up to 50 percent.

Seamless integration into existing production environments

Due to its compact dimensions, the ICON V-Drive Bodymaker can be seamlessly integrated into existing production environments. The die is extremely easy to change, resulting in a corresponding decrease in downtime and set-up times. Schuler expects product changeover times of around one hour for alterations to the can’s length and 2 - 3 hours for alterations to the diameter of the cans being produced. Servo presses also generally require much less maintenance than conventional machines.

With its new ICON V-Drive Bodymaker, Schuler has created a machine which combines efficiency and sustainability: Material consumption is greatly reduced and efficiency increased, while at the same time guaranteeing superior quality even when using recyclable materials.

---