CapWatcher Compact: Big on Quality. Small in Footprint.

Our new CapWatcher Compact combines a sorting, feeding and inspection unit for the quality control of plastic closures in a single, compact solution. Based on many talks with our customers, the system addresses one of the largest problems in modern production facilities – the availability of space! The CapWatcher Compact saves up to 50% of the floor space compared to conventional solutions and simultaneously maintains INTRAVIS’ renowned commitment to quality.

Efficiency and precision in a limited space

Manufacturers of plastic packaging are increasingly faced with the challenge of fitting more and more production capacity into limited space. This is where our new CapWatcher Compact comes into play: It combines three previously separate elements of the plastic closure production line – sorting, feeding and inspection – in one compact housing, without compromising on functionality or inspection quality.

"With the CapWatcher Compact, we have created a solution that takes our customers' production realities into account. We offer a reliable 100% inspection with minimal space requirements," explains Marius Pötting, our Product Manager Caps & Closures.

Development in dialog with the customer

The impetus for the development of the CapWatcher Compact came from customer requests over the last year. “During the last year, some of our customers came to us and said that in the future it will be more difficult for them to use our solutions, since the space in their production lines will be more and more limited. They were very sorry for that since they appreciate our sophisticated systems”, explains Marius. That was the moment we realized that there is a requirement to enable our proven inspection performance in a significantly smaller space.

Within six months, our development department created an initial prototype. However, it quickly became clear that simply reducing the footprint of the inspection unit would not provide the necessary space savings. Only by combining several downstream elements, the necessary reduction in space requirements would be achieved. So, in a second project phase, we developed and implemented an integrated sorting and feeding technology and finally brought the system to market maturity.

"Of course, it helped that we have been developing and building feeding solutions for plastic closures ourselves for many years in addition to vision inspection systems," says Marius. As a result, the system now has a footprint of just 2.4 m² (25,8 ft²) and therefore offers nearly the same inspection performance in half the space of a conventional setup.

Technical highlights of the CapWatcher Compact

Our CapWatcher Compact offers numerous technical functions that make it a sophisticated solution for inline plastic closure inspection:

• Integrated hopper and conveyor technology: The integrated hopper offers a capacity of up to 140 liters (37 gal). The feeder uses the familiar waterfall principle to efficiently transport closures into the inspection section.
• Comprehensive quality assurance: In addition to the standard modules for inner and outer closure inspection, unique and market-proven modules for micro hole inspection and cavity number reading are implemented. The top wall inspection (e.g. for inspecting prints for contamination etc.) is also available as an option.
• High speed: With an inspection performance of up to 40 closures per second, the system meets high-speed requirements.
• Second ejector: Despite the limited space, a second ejector is integrated, which can be used for sorting out quality shots or blacklisting, for example.
• Wide product range: The CapWatcher Compact is designed for the inspection of common CSD closures as well as tethered caps.
• Product-specific settings: The electrically adjustable jet height is saved for each product, and it automatically adjusts when changing products.
• Fault and jam detection: The system automatically recognizes (by implemented sensors), when faulty molded closures become jammed, and localizes the position precisely. This ensures uninterrupted and fluent production.
• Ease of maintenance: Despite the compact construction, the design allows easy access to all components thanks to doors on all sides.

To complete the downstream equipment, customers only need a cooling conveyor and a packaging unit in addition to the CapWatcher Compact – The whole periphery can be obtained from us as a turnkey supplier, of course.

Solution for modern production requirements

With its compact design, our new CapWatcher Compact addresses one of the most urgent problems in the industry: Limited space in production halls. Particularly in Europe, attempts are being made to produce more and more in the same or smaller space. With the integration of sorting, feeding and inspection into one unit, we now offer a space-saving and efficient solution.

"The CapWatcher Compact shows how important it is to adapt flexibly to the needs of customers. It is yet another example of how we at INTRAVIS see ourselves as a partner to our customers. We are always ready to take on new challenges. With the CapWatcher Compact, we are proud that we have created again great value for our customers as well as our industry in general," summarizes Marius Pötting.

For more information on the CapWatcher Compact get in touch with us.