State of the art closure production

Real-Cap deploys the most advanced injection technology, using multi cavity molds and high-speed assembly systems, resulting in an annual production capacity of up to 2 billion units. Our team operates a fully automatic production process and consists mainly of technicians and skilled operators. We use high- capacity injection machines and fast continuous assembly units running up to 120,000 units per hour.

Our choice of machinery and mold suppliers reflects our commitment to cutting edge technology, and includes some of the biggest names in the industry like Eckel & Sohn, Husky & Curtil.

Closure Components Production Process:

1. Raw Material

Our materials are imported from the biggest resin suppliers in Europe and USA, and comply with the latest food-contact standards and regulations. Three main plastic materials are used: HDPE, LDPE & PP.The materials are fed directly from the truck containers into the Silos system and then to the injection machines, through automatic feeding equipment.

2. Injection

Real-Cap is using multi cavities molds and high capacity injection machines - separate machine and mold for each component of the final products: Cap, Spout or Cutter.

Sophisticated production management software operates individual dosing units installed on each machine to mix raw materials with different additives in accordance to the product recipe.

Injected and inspected components are carried automatically by conveyors to the assembly machinery.

The injection area, where injection machines are located, contains also several conditioning silo systems for components before assembly. The area is fully air-conditioned and acomodates a molds-refurbishment department as well.

3. Assembly

The assembly of the injected components is done in a fully climate-controlled space The assembled units are automatically inspected and measured several times prior to packaging.

Packaging of the products in pre-erected carton boxes happens only after products are fully inspected and counted.

4. Packaging & Storage

In the separated packaging area where carton boxes are erected and pushed to assembly machines, full cartons are returned and sealed, then palletized and stretch-wrapped.

Each carton box is marked with a bar-code label during its filling, including all relevant production information for full traceability.

An automatic mobile trolley collects boxes from assembly machines and leads them into the closing and sealing systems. Closed carton boxes are carried automatically by conveyors to palletizing robotic systems, where bar-code scanning identifies the product in each box, boxes are weight-checked and all boxes taken to their direct pallet location.

The complete pallet is then inspected again and prepared for sea transportation, wrapped with stretch film and fitted with corner protectors, marked with ID label and eventually loaded into containers upon logistic order, or stored in the warehouse.