22.04.2008

Beutler special presses guarantee utmost quality and efficiency for forming of aluminum foil

Aluminum foil containers are one of the packaging industry’s fastest growing segments. As consumers increasingly make purchase decisions directly in the store, there is a growing demand for packaging which helps producers differentiate their products. Moreover, the pack’s aesthetic appeal and usability also play an increasingly important role. For example, several billion containers are produced every year for innovative capsule systems used for coffee and other hot beverages. This increased demand represents a major challenge for production systems. At the same time, rising raw material prices are placing further pressure on costs. Manufacturers are therefore calling for highly efficient and reliable production solutions. The Swiss press manufacturer Beutler Nova, a subsidiary of the Schuler Group, has tailored its range to meet exactly these requirements. Together with Leuthold Mechanik and Berhalter, the company also operates the Swiss Competence and Training Center, where packaging manufacturers can configure, test and coordinate complete production lines.

Beutler PAL 400 and PAZ 630: tailored system solutions for aluminum and tinplate forming

Beutler Nova’s two presses PAL 400 and PAZ 630 were developed specifically for the forming of aluminum and tinplate. The lines are based on tried and trusted Beutler presses, which the company has tailored to the special requirements of the “form, fill and seal” process chain. The machine’s frequency-controlled drive via a counter-shaft provides an extremely high working capacity and the pneumatic ram counterbalance guarantees optimal operation. Quick and simple stroke adjustment also facilitates fast changeovers. The lines boast press forces of 40 (PAL) and 63 tons (PAZ). Operators can set speeds of 40 to 150 strokes per minute. One decisive benefit for the production of packaging is the design of the electronic cam unit Dataplus 200, which enables direct accessing of die functions. This is particularly important as the decisive know-how for aluminum forming is in the die.

Optimal interplay of die and press eliminates micro-tears

The wall thickness of aluminum containers is generally between 70 and 120 µm. Due to the required properties and current high raw material costs, the materials used are becoming ever harder and thinner. The resulting technical demands placed on the production equipment can only be met if there is optimal interplay between die and press. The greatest challenge comes from micro-tears in the material. In close cooperation with Leuthold Mechanik, Beutler has developed its presses over the past few years in such a way that micro-tears can now be eliminated. Utmost quality is also ensured by the HLM SM 284 Vision Control System developed by Leuthold, which automatically rejects any defective products – even at top speeds of up to 1,600 containers per minute.

Swiss Competence and Training Center – fast implementation from idea to reliable packaging production

Users can observe this optimal interplay of die and machine in action at the newly founded Swiss Competence and Training Center, which is jointly operated by Beutler Nova, Leuthold and Berhalter in the Swiss town of Samstagern. Leuthold provides the complete die technology, stacking system and scrap disposal, while Beutler Nova supplies the presses and Berhalter the stamping technology for lid production. The center offers a number of lines for users to test, tryout and coordinate dies and machines over a period of several weeks. Customer staff can also receive professional and personal training on the machines. In the case of new orders, the required production lines can be operated at the Center during setup until the desired container volume has been achieved. Only when the entire line is running smoothly is it taken for installation on the customer’s premises. The benefit: existing production can continue without disruption. Because the setup is not carried out at the customer’s factory, the start-up time can be kept to a minimum and initial costs reduced.

Learn more about Beutler presses and the Swiss Competence and Training Center at the Metpack fair from April 22 to 26, 2008 in Essen, Germany, Hall 3, Stand 324.