Following innovations on the CCM feed process and solutions designed to speed up size and color changeovers, we now turn to a new set of integrated systems on the SACMI 4.0 line. In this third episode, we’ll take a closer look at the SFM slitting-folding machine, which incorporates new solutions that check the tamper-evident band pull force (PFMC), and the CVS154 vision system. Visitors to Chinaplas 2022 will, then, have the opportunity to experience all the latest from SACMI at the Shanghai international fair.

Crucial to prevent counterfeiting and ensure the best possible consumer experience, tamper-evident band slitting and folding solutions form the cornerstone of the SACMI 4.0 closures line. The goal is twofold; first, to create a fully integrated process with upstream production of caps by CCM machines (as described in the previous episodes); second, and above all, to perfect slitting-folding quality control by integrating downstream vision systems that can, from a digital manufacturing perspective, return the information needed to improve the entire process.

Slitting-folding solution by SACMI. With over 2,000 units already distributed worldwide, the SACMI-made SFM is the gold standard for applications of this type thanks to outstanding slitting-folding flexibility, versatility and quality.

On the application showcased at Chinaplas (SFM 12L) the machine automatically slits and folds caps arriving from the feeder by way of the servomotor-driven automatic blade positioning system.

New SACMI PFMC, in-line control and inspection of TE band. Innovations include the ability to pair the SFM with the new PFMC. The latter, which has an extremely compact footprint, allows cap samples (processed by the SFM) to be picked according to needs-based intervals and parameters and then tested for proper slitting performance.

The PFMC inspects the band slitting zone before proceeding with TE bridge break testing. Keeping this parameter under control is crucial as it ensures not just perfect slitting quality but also the required ease-of-opening (i.e. band bridges must snap easily in a coordinated way as the cap is turned).

CVS 154, a vision system r-evolution. SACMI is the world’s only solution provider to offer a dedicated vision system for every single stage of production on cap, preform, label and bottle lines. In addition to the additional check performed by the PFMC, the presented solution features a system downstream from the SFM slitting machine that lets manufacturers identify a complex series of on-cap defects, on the inner surface, the body and even the side wall.

First comes the inside, where the system detects defects in the gasket (cracks, sealing defects) and on the thread (deformation, voids, contamination, black spots). The second image captured by the system (cap body) allows for detection of any defects in the structure and, once again, in the tamper-evident band; the latter may include ovalization, small breaks, an incomplete band or slight color variations.

Lastly, a 4-camera system constructs a perfect 2D image of the side wall. This approach eliminates any potential distortion on account of optics, position or perspective. In addition to identifying defects invisible to the human eye - such as tiny scratches or imperfections - the system takes indicative measurements of the external and internal diameters of cap and gasket, again detecting any broken or faulty band bridges.

Digital re-action. A configuration of this type has several advantages. From a process control perspective, one of the most important is that the CVS can match an individual inspected cap with the number of the mold cavity in which it was made. This allows manufacturers to respond promptly to rectify - even automatically - any deviations or problems upstream from the process. This is done not just by discarding the faulty cap but by preventing the defect at origin, thus achieving the primary goal of a modern computer vision system.

Waiting 4 you at Chinaplas 2022! (SACMI booth 2.1F61)

Stay Tuned!