Packaging
GROWTH MARKET METAL PACKAGING: FORMING SPECIALIST SCHULER EXTENDS RANGE WITH NEW NECKING MACHINE
Thursday 25. June 2009 - New necking machine N40 from Hinterkopf
Whether beverage cans, spray cans or capsules and dishes for the food industry – the market for metal packaging is huge. According to the sector association APEAL, some eleven billion steel aerosol cans are produced every year. Almost another six billion cans are made from aluminum. The figures for beverage cans are even more impressive: experts believe around 230 billion aluminum cans are produced every year. The Schuler Group has long been well represented in this sector. With its cupping presses for the production of two-part beverage cans and a new generation of impact extrusion presses, Schuler has established itself as a systems partner for equipment used by the packaging industry. Based in Göppingen, Germany, the press manufacturer has installed some 2,500 lines – 800 impact extrusion presses alone – around the world since the 1960s. With the development of a new necking machine for the company Hinterkopf, Schuler has now expanded its range of products for the packaging industry.
Aerosol cans are produced on complex machines which combine a number of technologies. So-called aerosol can lines integrate every processing stage for the production of cans or tubes – from aluminum coil or circular aluminum blanks to the finished packaging product. Before the cans make their way to the supermarket shelf, they only have to be filled and sealed. Global market leader in this field is the German company Hinterkopf, founded in 1962 and based in Eislingen, Germany. Their lines boast both high output and quality as well as a modular concept which offers users a high degree of flexibility.
Launched in 2006, Schulers XS range represents a new generation of impact extrusion presses. With press forces of 150 to 400 metric tons, they are important components in Hinterkopfs forming operations. A total of twelve of these cutting-edge lines have so far been installed around the world.
New necking machine removes production bottleneck and offers completely new design possibilities
“The bottleneck in the production of modern aerosol cans are the so-called necking machines,” explains Alexander Hinterkopf, CEO of Hinterkopf. He adds: “With the previously available models, it was impossible to produce specially formed or embossed packaging. But such body shaping and embossing is high on the list of customer wishes.” If at all, such forming operations could previously only be realized on complicated – and thus often error-prone – double or triple machines. The experts at Hinterkopf and Schuler therefore began the development of a new necking machine in summer 2007.
“We focused in particular on the aspects of increased output, greater flexibility and enhanced quality,” stresses Markus Röver, head of Schulers Highspeed division. He adds: “We achieved this with a machine concept which takes an holistic approach to the decisive elements: body, slide guiding and drive. By separating the 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 at 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 25-millimeter steps up to a maximum length of 325 millimeters to enable body shaping. This maximum stroke length means that cylinders of up to 175 millimeters long can be formed. The machines maximum output varies according to the stroke length. Up to 240 cans per minute can be produced with a short stroke (150 millimeters) and 150 cans per minute with a long stroke of 275 millimeters.
Successful division of labor and high degree of vertical integration guarantee top quality and machine availability
Schuler supplies the complete machine with all components, i.e. drive, slide guidance and large components, to Hinterkopf. As the turnkey supplier, Hinterkopf is then 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 customers facility.
“We decided to cooperate with Schuler because the basic design of a necking machine corresponds to that of a press with regard to its slide guidance, drive system and movement characteristics,” says Alexander Hinterkopf. “As a press specialist, Schuler was therefore our first choice for technology. Further reasons were the high degree of vertical integration guaranteeing high quality for us and our customers, and of course their close proximity,” adds Alexander Hinterkopf.
Schuler manufactures all cast and welded parts for the machines itself. This also guarantees short delivery times should customers require replacement parts. Schuler is also quickly on site when it comes to service activities. Its network of global service centers ensures fast reaction times to maintain high machine availability. Schulers head office in Göppingen is just five kilometers away from Hinterkopfs headquarters in Eislingen. Customers and potential clients can therefore easily inspect the complete line in operation before turnkey delivery.
Comprehensive offer for the packaging industry
In addition to lines for aerosol can production and cupping presses for the manufacture of beverage cans, the range of products for the packaging industry is rounded out by presses supplied by Schulers Swiss subsidiary Beutler Nova. 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. “Against the backdrop of high raw material and energy costs, and excess market supply, there is a growing demand within the packaging industry for efficient and innovative solutions. The general trend is toward material savings and resource efficiency, while at the same time there is demand for new and attractive designs which appeal to consumers. The combination of these two aspects is only possible with modern technology and especially high-precision forming machines,” says 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 Schulers 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.