Ever wondered about the journey of your favourite beverage from the manufacturing plant to your hand, all contained in a sleek, shiny can? While we often take these everyday items for granted, the process of making a can is a fascinating tale of precision engineering, advanced machinery, and innovative technology.
Did you know that canmaking begins with a colossal 13-ton roll of aluminium sheeting? This giant roll is capable of producing an astonishing 750,000 cans! The transformation starts as the metal sheet is pressed into circular blanks, which are then shaped into cups. From there, the cups undergo a series of intricate processes, evolving step by step into the finished cans that line our supermarket shelves.
Join us as we unravel the intricate process of canmaking, step by step, and explore the incredible machines that turn raw materials into the durable, recyclable containers that keep our goods fresh and secure.
Step 1
The first stage in forming a can involves creating a cup shape from the metal sheet. This process is done with the help of the Cupping Press – which cuts circular blanks from the metal sheet. The blanks are then drawn into shallow cups using a punch and die mechanism.
Step 2
Next, the Bodymaker takes the preformed shallow cups and stretches them into their final shape. This process involves drawing the cup through a series of rings that elongate the cup and thin its walls, a technique known as “drawing and ironing” (D&I). The precise control of this process ensures that the can body is uniformly thin and has the required height and diameter.
Step 3
After the cups have been drawn and ironed, the Trimmer trims the excess material from the top of the can to achieve a consistent height. This step is crucial for ensuring that all cans meet the exact specifications required for further processing and final assembly.
Step 4
The newly formed cans then move along to the Washer on a conveyor belt. Here, the cans are washed meticulously under a 6-stage cleaning process with chemicals and deionised water, at a controlled temperature. The cans emerge from the washer all glossy and shiny, ready to enter the drying stage.
Step 5
After washing, the cans are passed through a drying oven to eliminate any remaining moisture. This stage ensures that the cans are completely dry, providing a clean and stable surface for the subsequent process of printing. Proper drying is essential to maintain the integrity of the can and ensure flawless adhesion of coatings applied later.
Step 6
The freshly cleaned cans are decorated and branded by a Decorator. Printing up to 2000 cans per minute, the CMbE reformat™ Decorator uses a rotation printing system with 8 inkers, each operated by its own independent motor, ensuring efficient and precise printing. In the end, a layer of varnish is applied to the cans to protect the ink, following which they make their way to an oven to dry off.
Step 7
The Pin Oven Stage in canmaking is essential for curing the freshly applied ink on the cans. In this stage, cans are securely placed on pins and transported through a heated oven. The controlled heat ensures the ink bonds properly to the can’s surface, enhancing durability and preventing smudging. This process sets the foundation for a long-lasting, high-quality finish, ready for further processing or filling.
Step 8
The cans now enter our state-of-the-art Lacquer Spray Machine that sprays a water-based varnish on the inside of the cans. This varnish acts as a barrier between the drink and the aluminium, protecting the drink from the metal, while also protecting the metal from the drink.
Step 9
Next, the cans pass through an Internal Bake Oven, which is crucial for curing the internal lacquer coating applied to the cans. Here, cans are subjected to controlled heat to ensure the lacquer adheres properly and creates a durable, protective layer. This coating safeguards the can’s interior against corrosion and preserves the quality of its contents, ensuring the cans are ready for filling and sealing.
Step 10
Finally, the cans meet the Die Necker – a specialised machine tasked with reducing the diameter of the top portion of the can body to prepare it for sealing with an end. This crucial step, known as necking, ensures that the can has the correct dimensions for the end attachment and helps in creating a strong and secure seal. Once this stage is complete the can then travels on to the palletizer and is stored ready for shipping.
And there it is! The perfect can.
It is important to note that every can goes through a sophisticated vision system that photographs the inside of the can. Any can that doesn’t meet the quality standard is sent back for recycling, along with the leftover sheets of aluminium from Step 1.
The canmaking process is a marvel of modern engineering, involving numerous specialised machines that work in harmony to produce high-quality, reliable packaging. From raw material preparation to the final inspection, each step is crucial in ensuring that the cans we use are not only functional but also safe and aesthetically pleasing.
At CMbE, we are proud to be at the forefront of this industry, providing innovative solutions that enhance efficiency, flexibility, and sustainability in canmaking. Furthermore, our expertise extends to Trackwork & Conveyance, ensuring smooth and efficient transportation of materials throughout the production line. Our state-of-the-art Tool Shops provide precision tools and custom solutions tailored to specific manufacturing needs.
Additionally, through our trusted partners, we offer full turnkey solutions, managing every aspect of the production process from initial design to final implementation. This holistic approach allows us to deliver integrated, seamless solutions that optimise efficiency, enhance productivity, and ensure the highest quality standards in the industry.
Visit our website www.cmbe.com to learn more.
