Speed, yet more notably, throughput (rework or disposal costs). In a perfect globe, the capper would have no defects. The takeaway here is that the higher the reject rate, the longer it takes to fulfill a client order.
Rework or disposal expenses most likely merits a spot on the leading 10 capping machine manufacturers list of issues, but is typically neglected or forgotten. These can be hidden costs. All cappers will have rejects, primarily from 3 major variables: mechanical considerations, issues with containers or caps and user concerns Beyond the extra runtime needed to offset the declined containers, consider the costs related to remodeling or disposal of the product, caps, containers, and more, along with labor and administrative variables.
Speed (throughput) reviewed above dealt with the additional time to run a job. Beyond all the prices associated with turns down, what is the impact of higher reject rates on your procedure? Are rejected containers remodelled or discarded? If discarded, what is the expense? If remodelled, what will be the expense? Are you introducing more labor to treat failings of an inadequate automation solution?
On numerous instances we have seen operators placed after cappers to correct every container leaving the capper. What attributes does the capper have to lessen rejects? Does the capper have a sensing unit to spot a cross-threaded or missing cap that will hinder torquing in the 2nd station that otherwise could bring about a jam-up? Perfect placement of the cap + ideal torque control = ideal induction securing.
Does the capper employ self-diagnostics to help in repairing in case of a fault?
Spares and wears
How do extra components integrate into your operation? What is the effect of extreme downtime on your procedure? Does the capper supplier supply a consumables package and spare parts sets with the tools quote?
Container and cap tolerances
An essential factor to consider usually disregarded is cap and container quality including out-of-round, oblong or warped caps, falling liner, irregular bottle wall density, and sharp sides on threads from a worn mold. It is critical that your capper supplier extensively tests and reviews as needed to ensure the capper will generate as estimated. Typically automating a process that was done manually reveals other component concerns where the automation approach is much less forgiving to concerns with caps or containers.
The requirements of torquing vary from “I require it rigid” to “All torques require to be tracked and stored.” Does the maker offer the option of mechanical clutch and servo as well as choices for torque data management? Servo torque application is one of the most accurate ways to manage application torque. Consistent surveillance of applied torque can prevent loosened caps from continuing downstream. Can the capper promise no loosened caps leaving the system?