GERMANY – KHS has unveiled a new system designed to optimize the filling of lightweight, thin-walled beverage cans in response to rising demand for sustainable packaging.
The solution enhances efficiency and ensures that modern can designs, which use fewer resources, maintain structural integrity during the filling process.
Manufacturers increasingly adopt thin-walled cans as the beverage industry shifts towards eco-friendly packaging to reduce material use and minimize environmental impact.
However, these cans present unique challenges during filling due to their reduced wall thickness, which can now withstand a maximum pressure of just 675 newtons, compared to 800 newtons for traditional cans.
Andreas Krieg, from KHS’ Wet Section Technical Support Department, emphasized the importance of adapting filling technology to meet these new requirements.
“Our system for gentle filling ensures the cans remain intact while maintaining high operational efficiency,” he explained.
Flexible retrofit solution boosts efficiency
KHS has introduced a conversion kit to help beverage producers retrofit their existing can fillers, ensuring seamless compatibility with lightweight, thin-walled cans.
This solution addresses the challenges posed by reduced wall thickness, which demands more precise handling to avoid damaging containers during filling.
A key feature of the conversion kit is the inclusion of adapted bell guides, which can be customized with either Teflon expansion joints or elastomer seals.
The choice of material depends on the filler’s year of manufacture, offering flexibility in adapting older equipment to new requirements.
These components enable smooth and reliable contact between the filling valve and the can, safeguarding the can’s integrity.
Additionally, the kit features optimized pneumatic cylinders that allow for precise pressure control and adjustment.
This ensures that the contact pressure can be finely tuned to match the specifications of lightweight cans, reducing the risk of deformation or damage.
By integrating these enhancements, the retrofit preserves the machine’s performance and extends its operational versatility.
These modifications enable fine-tuning the filling valve’s contact pressure, safeguarding the cans during filling.
Notably, the retrofits can be implemented during routine maintenance, minimizing downtime and maximizing flexibility for plant operators.
Additionally, KHS offers comprehensive support in collaboration with Swiss partner Ferrum, providing seamer conversions essential for compatibility with lightweight can.
“We coordinate the entire process for customers, ensuring seamless integration of the components and technical expertise,” Krieg noted.
Positive market feedback and availability
KHS began testing the conversion kits in early 2024 with select customers, receiving overwhelmingly positive feedback.
“Our tests confirm both the efficiency and durability of the retrofitted systems,” Krieg said.
Following successful trials, the retrofit solution is now available to beverage producers worldwide, providing a sustainable, efficient path forward for handling lightweight cans.
By offering this innovative solution, KHS continues strengthening its commitment to resource-saving technologies, helping beverage manufacturers improve sustainability and maintain competitive advantage.
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