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MANUFACTURING PROCESSES
1.1 Aluminium Can
Our twopiece beverage can is produced in a continuous process, which converts aluminium into cans. The process incorporates metal-forming, cleaning, internal and external treating and coating, and the application of final decoration.
Step 2
The aluminium coil is cut into strips. The strip is lubricated with a thin film of oil and then fed continuously through a cupping press which blanks and draws thousands of shallow cups every minute.
Step 3
Each cup is punched through a series of tungsten carbide rings. This is the drawing and ironing process which redraws and literally thins and lengthens the walls of the cans into its final can shape.
Step 4
Trimmers remove the surplus irregular edge and cut each can to a specific height. The surplus material is collected and recycled.
Step 5
The trimmed can bodies are passed through highly efficient washers and then dried. This removes all traces of oil in preparation of the internal and external coating.
Step 6
The clean cans may be base coated externally with a clear or pigment base coat which forms a good surface for the printing inks.
Step 7
The cans pass through a hot air oven to dry the coating.
Step 8
The next step is a highly sophisticated printer/decorator which applies the printed design - up to six colours, plus a varnish.
Step 9
A coat of varnish is also applied to the base of each can by a rim-coater.
Step 10
The cans pass through a second oven which dries the inks and varnish.
Step 11
The inside of each can is sprayed with lacquer. This special layer is to protect the can from corrosion and its contents from any possibility of interaction with the metal.
Step 12
Internal and external lacquered surfaces has already been dried in an oven.
Step 13
The cans are passed through a necker/flanger. Here the diameter of the wall is reduced or 'necked-in'. The top of the can is flanged outwards to accept the end once the can has been filled.
Step 14
Every can is tested at each stage of manufacture. At the final stage it passes through a light tester which automatically rejects any cans with pinholes or fractures.
Step 2
The sheet is fed through a press which stamps out thousands of ends every minute.
Step 3
As the ends are stamped out the edges are curled at the same time.
Step 4
The newly formed ends are passed through a lining machine which applies a very precise bead of compound sealant around the inside of the curl..
Step 5
A video inspection system checks the ends to ensure they are perfect.
Step 6
The pull tabs are made from a narrow width coil of aluminium. The strip is first pierced and cut and the tab is formed in two further stages before being joined to the can end.
Step 7
The ends pass through a series of dies which score them and attach the tabs, which are fed in from a separate source.
Step 8
The final product is the retained ring pull end.
Step 9
The finished ends, ready for capping the filled cans, are packaged in paper sleeves and palletised for shipment to the can filler.
Step 1
A vacuum draws mixed virgin and reformed pellets into the drier. The resin is dried to below a moisture content of 50ppm (particulates per million).
Step 2
After several hours, the blended resin is injected into the preform mould and clamped, resulting in the production of the embryonic bottle.
Step 3
The preform is heated by heater boxes with several variable lamps. The settings of these lamps is called the profile.
Step 4
The preform is transported into the mould. A hot preform is clamped in a blow
Step 5
A stretch rod enters the preform and stretches it lengthwise.
Step 6
Low pressure air is blown into the preform to form the main part of the bottle.
Step 7
High pressure air is blown into the bottle to fill out the details like the feet and any markings (e.g. logos)
Step 8
The air is allowed to escape from the bottle and this time in contact with the chilled mould allows the bottle to crystallise. Time is allotted in the cycle to depressurize the mould before opening it and removing the bottle.
THE PROCESS (1) Rolls of paperboard are delivered to VisyPak Broadmeadows. (2) The rolls are printed in up to 5 colours, (3) Paperboard is coated to a composite laminate that includes Aluminium foil and low density polyethylene. (4) The coated paperboard is then cut into individual blanks and creased to assist folding on the filling machine later. (5) The sleeve is folded, (6) and the seam sealed. (7) The sleeves are inspected then packed and dispatched to the customer.
THE PROCESS (1) Rolls of paperboard are delivered to VisyPak Broadmeadows. (2) Paperboard is coated with low density polyethylene. (3) The rolls are printed in up to 4 colours, (3) cut into individual blanks and creased to assist folding on the filling machine later. (4) The sleeve is folded, (5) and the seam sealed. (6) The sleeves are inspected then packed and dispatched to the customer. (7) The sleeves are fed onto the filling machine, (8) where the bases are constructed. (9) The cartons are formed, filled and finally top sealed. (10) The finished cartons are conveyed downstream where they are packed ready for distribution.
Step 2
2a. PurePak - The lamination of the paperboard through an extrusion coating process. As a reel of paperboard unwinds through the extrusion line, the first extrusion station applies a layer of polyethylene on the inner face of the paperboard.
2b. A second extrusion station applies a shiny or gloss Polyethylene to the outer face of the paperboard. This layer is corona treated to ensure good ink adhesion. Combibloc - This step for Combibloc is completed after the printing process.
Step 3
3a. Paperboard is printed via lithographic/ offset printing press for CombiBloc. CombiBloc The rolls are printed up to 6 colours 3b. Flexographic technology is used for PurePak. PurePak -The rolls are printed up to 4 colours
Step 4
Combibloc - During printing, a clear varnish known as adhesive is applied to a defined area (pouring spout) of the top sealing flaps.
Step 5
Both - Then fed into a machine called a converter where the reel of laminated paper is printed, and then cut and creased, in individual flat blanks that are automatically stacked ready to be flame-sealed into finished carton blanks. CombiBloc - As the web unwinds, it is embossed with creases, slit lengthwise and cut into blanks that are stacked onto pallets ready for the next process. Correct position and depth of creases are essential to ensure cartons run efficiently through the filling machine.
Step 6
Both - The flame sealer is loaded with the flat blanks from the converter and these blanks are continuously fed, individually, in to the machine. CombiBloc - A gas flame melts the polyethylene in order to seal the opposite edge to the blank, with pressure applied with a pressure roller. The sleeves are then folded back and forth along the vertical creases, to assist opening in the filler.
Step 7
The finished cartons are then counted, and automatically boxed and palletised, before being stored in the warehouse ready for despatch.
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Step 8
Carton Filling The sleeves are fed into the filling machine where the bases are constructed. The cartons are formed, filled and finally top sealed. , neck dimensions and bottle weights are very accurate.
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