Recorp NZ
Recognizing a growing need for cans in New Zealand, Recorp NZ needed a supplier capable of supporting brands of all sizes to...
Read MoreThe Challenge
Recognizing a growing demand for cans in New Zealand, Recorp NZ saw a key market opportunity for a supplier that could support brands of all sizes. By positioning itself as a full-range supplier, its goal is to meet the needs of customers of all sizes, offering a diverse array of can sizes with low minimum order quantities. Building a business around flexibility, Recorp NZ needed a production line that could also support these requirements. Entering a highly competitive market with low tolerances, the company understood its approach would be challenging. Recorp NZ’s top priority was finding a supplier who recognized these distinct needs.
The Solution
Belvac tailored a solution to meet Recorp NZ’s specific needs, operating up to 1,800cpm while providing flexible operations to meet customer requirements. The front end commences with the Belvac Cupping System which feeds cans into eight Belvac BM24 Bodymakers and CC93 Trimmers. Utilizing a hypocycloid main drive, the Bodymaker has no foundation requirements, in addition to no vertical movements which results in low ram deviation, reducing tear-off rates and producing accurate body wall thickness. Belvac’s CC93 Trimmers produce high quality burr-free, sliver-free, step-free trimmed cans. The ARC Can Washer and Dry-off Oven have been engineered for energy efficiency, wastewater reduction and process optimization.
A unique aspect of this project is the configuration of the Decorator area. “The inclusion of a Basecoater and Pin Oven enables operators to apply a baselayer of ink, typically white, to the cans before label application, resulting in a more vibrant print due to enhanced pigmentation. After assessing Recorp’s needs, the Belvac team determined that the Decorator presented a probable area for bottlenecks. Anticipating frequent label changes, we opted to integrate a dual Decorator and Pin Oven system which will help reduce operational downtime while continually allowing Recorp to scale their contract sizes,” explained Tony Reynolds, Director, Integrated Solutions EMEAI.
The back end features eight Inside Spray machines that feed into an ARC Internal Bake Oven which is designed for optimal heat retention and minimized utility consumption. The line features two 595K VE Belvac Neckers, one of which is equipped with an intermediate infeed allowing for flexibility between producing multiple can sizes. The Necker turrets are standardized which reduces downtime requirements for can size changeovers and gives operators more flexibility to use common hand tools when making machine adjustments.
The addition of Belvac’s Intelligent Manufacturing System (IMS) and the High Speed Selective Sorter (HS3) provides operators real-time dynamic monitoring of the plant’s processes helping to locate the root cause of spoilage by tracking, grouping and prioritizing vision system defects of necking and upstream operations. This system allows operators to quickly review Pareto charts which group various defects, in addition to sampling and sorting without interrupting normal production speeds. Working in tandem, their features are optimized, reducing downtime and spoilage rates, while also improving quality control processes.
"Belvac delivered a comprehensive system tailored to our specific needs... To get a plant up and operating in eight months has been extremely challenging, however quickly making high quality cans has resulted in us entering the market and winning customers."
Flexibility Makes Successful Projects
Belvac provides turnkey lines rated up to 3,600cpm, with solutions available for lower volume production. In addition, Belvac specializes in lines with multiple size capabilities, like Recorp NZ. Another area of specialty for the company is bottle cans. Typically rated from 600cpm to 1,200cpm, these lines produce a variety of bottle configurations and shapes with multiple closure options. Existing can making lines may be fitted with bottle can cells for dynamic production output.
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