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We interview Kevin Heap,Packaging Expert atSumitomo (SHI) Demag

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CAPS ANDCLOSURES

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What does the process ofinjection moulding for thecreation of caps andclosures entail?

Melted and mixed underpressure by a rotating screwuntil there is a homogeneousmelt which is injected underpressure into mould.

In a nutshell - for theproduction of caps and closures- thermoplastic andthermosetting polymer granulesare fed into a heated barrelwhere they are melted andmixed under pressure by arotating screw until there is ahomogeneous melt which isinjected under pressure into amould cavity where the shape isconfigurated to the cavity and isreplicated exactly. The mould isthen cooled and opened ejectingthe finished cap/closure. Forcaps and closures, multi-cavitymoulds are used to allow theproduction of thousands of capsper minute.

How does injectionmoulding compare to othermoulding techniques?What are the advantages ofusing injection mouldingfor the production of capsand closures?

Compression moulding hasenjoyed a perceived ‘top of thepodium’ position with respect

to productivity for a long time,particularly for certain types ofbeverage caps and closures.Compression moulding is aforming process in whichextruded plastic melt is croppedand loaded into a single cavitythe cap is formed into shapeand ejected.

In recent years, injectionmoulding solutions havesurpassed the capabilities ofcompressions moulding,particularly for single piecewater enclosures. Withadvances in mould design,materials and high performanceinjection moulding machinery,such as the Sumitomo (SHI)Demag El-Exis SP 450 tonnefast cycling machine, the newschoettli 96 cavity mouldenables high productivity of150,000 parts/hour - astaggering 2.2 second cycletime for 96 caps which resultsin low unit costs, highefficiency and outstandingeconomic viability.

The injection mouldingprocess is very flexible with theclosure design, it allows the capmanufacturer to producecomplex speciality closureswhich you cannot be producedwith compression moulding.Manufacturers are oftencontracted to produce millionsof caps and closures, so to be

cost effective, invest in highperformance plant equipment isadvisable. Packaging formatsare constantly changing to bemore in keeping with modernlifestyles such as sports caps,gabletop cartons, asepticcartons and stand up pouches,it makes good economic senseto build a complete mouldingsystem for each individualclosure. Where a manufactureris completing small batch runswith a large product portfolio,moulds can be designed forrapid changeover. Once a cap ismoulded, zero post productionoperations are required due tomoving core operated by themould and injection mouldingmachine. From a sustainabilitypoint of view, bio plastics arealso being developed to meetmanufacturer’s green credentialrequirements, plus a furtheradvantage is that any scrapmaterial from any type of plasticcan be reground and reused,which means very little waste.

What trends do you foreseeunfolding in the caps andclosures sector?

According to a new study* byThe Freedonia Group worlddemand for caps and closures isprojected to rise by over 5% peryear to $46 billion in 2016, sothe outlook for performance

Caps & ClosuresPackaging Gazette talk to Kevin Heap Packaging Expert,Sumitomo (SHI) Demag about current trends and challenges

44 | Packaging Gazette | PackagingGazette.co.uk

CAPS & CLOSURES

Kevin Heap, CentralArea Sales Manager atSumitomo (SHI) Demag

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injection moulding equipmentsuppliers looks optimistic. Overthe last two years, Sumitomo(SHI) Demag UK, manufacturerand system integrator ofinjection moulding equipment,has seen substantial growth inthe beverage market asmanufacturers updatepackaging formats to makemore consumer friendly capsand closures in-keeping withmodern day lifestyles. Theseinclude sport style caps, whichare generally more expensivethan standard types but arefavoured by consumers for theirconvenience and ease of use.This segment is expected to seethe fastest gains among majorplastic closure types. While thepopularity of single-servingbottles will stimulate unit gains,using light-weight materialswith less costly enclosures willbe essential for survival.

Another growth area forSumitomo (SHI) Demag is thepharmaceutical market. Suppliersof caps and closures need to get agrip on regulations and standardswhich include child-resistance,elderly-friendly and tamperevident packaging.

With material still being thelargest cost element of a closure,thin walling and weight reductionhas been the theme for the lastfew years and will continue.Production and process efficiencyare keywords, with a greaterdemand from manufacturers foran integrated system approach.Polypropylene will remain theleading caps and closure resinwith expectations that thematerial may be replaced withHDPE which has economic andsustainability advantages.

What challenges do you face?The ‘more for less’

philosophy is highly evidentin our industry. Sumitomo

(SHI) Demag are constantlystriving to producelightweight caps and closureswhich help to lower costs,increase sustainability andsurpass speed/performanceexpectations. Demands tocreate smaller, lighter partshave made thin-wall mouldingone of the most sought aftercapabilities for an injectionmoulder. From a machinerymanufacturer point of view,thinner wall sections bringchanges in processingrequirements: higher

pressures and speeds, fastercooling times, andmodifications to part-ejectionand gating arrangements.

Our proven technology, inhybrid and full electricplatforms, enables us to offerthe right turnkey systemmatched to the customer’sexact requirements –specifically we are able tocalculate the total part price of acap/closure taking intoconsideration the capitalinvestment, for either a hybridand full electric system, so that

the customer can understandtheir ROI options - ROI is amajor influencer in thepurchasing decision.

Sumitomo (SHI) Demag hasfound increasing pressuresfrom manufacturers wantingnot only shorter cycle times,higher productivity and lowercosts per part, but moreenergy efficient machinery.The El-Exis SP is a hybridsystem which uses a carefullycrafted blend of drivetechnologies including a servodriven hydraulic clamp unit toachieve precise movements, ahydraulic accumulatordelivering high injection rates,and an electric screw drive forparallel plasticising, all ofwhich shave tenths of asecond off the cycle timeenabling manufacturers toprofit from increased marginsand lower energy bills. Withenergy prices continuallyrising, we can only foresee thatto stay ahead, energy efficientmachinery will remain at thetop of the product designdrawing board. �

CAPS & CLOSURES

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