We have an injection machinery (for up to 500 tonnes) and multi-cavity moulds (with up to 96 cavities), purchased from companies of worldwide renown in the packaging sector.
Ourautomated system means there is no direct human interaction with the caps or the packaging from the time the material arrives at the silos until just before the finished product enters the warehouse.
Quality control systems are located on the lines, equipped with computer vision cameras capable of checking every cap manufactured.
Our process is divided into the following phases:
The lorries pump the material into the silos where the raw material for manufacturing our products is stored.
Storage conditions are completely hygienic, comply with the strictest standards for food use and prevent human contact with the product.
The raw material comes from the exterior silos to the feed room through stainless steel conduits.
Next, the equipment in this room mixes the raw materials and dyes required for each product.
Following this, the feeders send the mixture to the hopper of the corresponding injection machine.
The atmosphere of this room has controlled temperature and humidity levels, and
houses 40 of the latest-generation injection machines with 150 to 500 tonnes of clamping force and moulds with 32 to 96 cavities.
Given the requirements for the hygiene and bacteriological monitoring of the caps, the room features an air micro-filtration system that has enabled us to attain a class 100,000 certification.
This is a room with filtered and monitored air where the fully automated production process continues.
The parts are subjected to rigorous quality control using computer vision cameras and regular visual inspections.
We have a fully automated logistics system using laser-guided vehicles.
These vehicles transport the empty boxes – with bags that are put into place automatically – to each reception area for the caps coming from the injection room; they collect the boxes filled with the caps and transport them to the labelling area for identification and subsequent sealing.
We have an automatic labelling system which ensures full traceability for each and every one of the boxes.
The entire packaging process takes place under the best conditions of hygiene by means of a fully computerised handling system that avoids human contact.
This area is also where the machines for assembling two-component caps are located.
End of line
The completely closed and identified boxes on the conveyor belt move to the end-of-line area, where they are palletised.
They are then strapped, and ready for storage.
This palletising is tailored to each client’s needs.
Our warehouses are of appropriate size and meet the most stringent of hygiene standards.
We have safety stock for our clients and can hold up to 150 lorries in reserve.