Proprietary can seamer handles up to 135,000 containers per hour

Can sealing centres around what is known as the double fold process, in which the cover and the can body are folded together mechanically in a number of steps, with five material layers in total having to engage precisely in each other. This seam must be absolutely tight if the product is to be protected from contamination or oxidation. For the customer, the sealing process is a critical part of the line performance, because this is where the most important quality parameters of the end product are largely determined.  

The market wants it – and Krones supplies it 

On top of this is the high mechanical stress to which the components are exposed due to the enormous number of cycles. A can seamer, then, must be not only precise, but also extremely robust and require as little maintenance as possible. It also needs to meet elevated standards of hygiene and cleaning. These requirements are nothing new in principle – Krones has been meeting them in practice with the Modulseam since as far back as 2017. This is primarily used in the filler-capper block known as the Modulfill Bloc FS-C. Krones didn’t develop it purely in order to meet the existing market requirements, though, but also to generate further added value for customers. 

The first step is always difficult  

To start with, Krones developed Modulseam versions for the medium performance range – and then kept on expanding the model series. It was a difficult undertaking from the very start – both technically and strategically. The aim was to generate a holistic concept across the whole block that meets our high hygiene standards, utilises the very latest servo technology and ultimately covers the entire performance bandwidth of Krones can lines. This represents a significant step forward in the features of the can line of the future. As they say, though, the first step is always difficult, and there were a few challenges to overcome in the development stage. “We placed great emphasis on the know-how of the entire 'can seaming’ application. To that end we invested in an ultramodern, fully parameterised test bench in the technical centre in Neutraubling,” explains Simon Gebendorfer from Product Management Filling Technology. “The aim was to process the whole range of can and cover formats currently on the market and be able to offer consulting services for new customer ideas – such as lightweight cans, new coatings and paints – with our equipment.” 

Ready for anything 

The optimised concept offers plenty of clever elements: The continuous servo drive concept allows all movement axes to be controlled precisely, reduces maintenance expenditure and improves process reliability. The Modulseam is also fully accessible from all sides, which makes format changes and maintenance considerably easier. Thanks to intelligent recipe management, automatic height adjustment and optimised handling parts, product changes can be completed in record time. Back in 2022 Krones invested in a training machine for the Academy that would give both its own service team and customers all over the world an opportunity to gain practical know-how on the machine.  

The Modulseam delivers when it comes to hygiene, too: Stainless steel components, compartmentalised drive sections and an inclined table top for targeted media drainage ensure a maximum degree of hygiene. Experience gained with the installed base and feedback from customers was taken into account, allowing further optimisation in terms of the design, cleanability and stability of the machine.  

The series has now been completed with the high-performance version, which handles up to 135,000 cans per hour with 18 capping heads. The first high-speed machines are already in the field. Between them, the models with four to 18 capping heads now cover the entire bandwidth of outputs and formats. 

A strong team performance 

“This project was really something special. It placed huge demands on us – from Development through the product lines all the way to Service and Lifecycle Service. We formed a team of new and experienced staff in almost no time at all, and the outstanding collaboration allowed each of us to play to our strengths,” explains Stefan Pöschl, Head of Can Technology in Filling Technology Engineering. “That enabled us to quickly refine an existing product that more than meets our customers’ expectations. The complete can filler and seamer block demonstrates the innovative strength that we at Krones have. And we are delighted that we will be able to deliver up to 50 machines to our customers in the next twelve months.”