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Leading Edge Technology
Our manufacturing process is based on technology developed in Japan by Daiwa Can Company for their aluminum "New Bottle Can" for beverages. The DSC version, adapted to steel and aimed at the aerosol market, has its own proprietary techniques.
Giant coils of tin-free steel arrive at our Batavia plant already coated with a thin layer of PET on each surface. In our coil-to-can process, they are directly converted into consumer-size aerosol cans at the rate of 600 per minute.
The steel passes through a cupping press, which forms large cups about five inches in diameter to a shallow depth. The second press draws the cups narrower and deeper to achieve the desired diameter and height.
After an initial trimming, the containers are ready for printing, which is accomplished in-line with up to eight colors on high-speed dry offset decorators. Because we have two decorators on each line, the changeover from one label to another is almost instantaneous. After printing, the cans travel through an oven to cure the ink and varnish.
A third press forms the rounded top. The containers are then trimmed again, after which the standard one-inch opening is formed. Finally, the open end of the cylinder is necked and flanged, and the bottom end is attached using a doubleseam.
In the final stage, the cans are layered onto pallets, stabilized and stretch-wrapped for shipping.
Our manufacturing process is based on technology developed in Japan by Daiwa Can Company for their aluminum "New Bottle Can" for beverages. The DSC version, adapted to steel and aimed at the aerosol market, has its own proprietary techniques.
Giant coils of tin-free steel arrive at our Batavia plant already coated with a thin layer of PET on each surface. In our coil-to-can process, they are directly converted into consumer-size aerosol cans at the rate of 600 per minute.
The steel passes through a cupping press, which forms large cups about five inches in diameter to a shallow depth. The second press draws the cups narrower and deeper to achieve the desired diameter and height.
After an initial trimming, the containers are ready for printing, which is accomplished in-line with up to eight colors on high-speed dry offset decorators. Because we have two decorators on each line, the changeover from one label to another is almost instantaneous. After printing, the cans travel through an oven to cure the ink and varnish.
A third press forms the rounded top. The containers are then trimmed again, after which the standard one-inch opening is formed. Finally, the open end of the cylinder is necked and flanged, and the bottom end is attached using a doubleseam.
In the final stage, the cans are layered onto pallets, stabilized and stretch-wrapped for shipping.
The shape of the future.
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Advantages in the Market
Lean manufacturing principles in effect:
Elimination of typical can manufacturing process wastes; overproduction, transportation (between plants/processes), waiting (between plants/processes), inventory/work in process, motion/energy,overprocessing, and defects
VSM: Eliminates many of the steps necessary in the production of three-piece cans
Throughput: Is rated to run significantly faster than three-piece and aluminum
PokaYoke: Significantly improves can quality, both by design and through process control
Results in approximately 14% less scrap than traditional three-piece manufacturing
SMED/Efficiencies: In-line dual decorators require far less setup time for changing from one label to another
Virtually eliminate leakage as a quality issue
Less energy
Convert coiled steel to a finished decorated can in approximately 20 minutes, virtually eliminating work-in-process inventory and maintaining flexibility for our customers
Automation and lean manufacturing techniques reduce the need for untrained personnel, unlike traditional can manufacturing
Lean manufacturing principles in effect:
Elimination of typical can manufacturing process wastes; overproduction, transportation (between plants/processes), waiting (between plants/processes), inventory/work in process, motion/energy,overprocessing, and defects
VSM: Eliminates many of the steps necessary in the production of three-piece cans
Throughput: Is rated to run significantly faster than three-piece and aluminum
PokaYoke: Significantly improves can quality, both by design and through process control
Results in approximately 14% less scrap than traditional three-piece manufacturing
SMED/Efficiencies: In-line dual decorators require far less setup time for changing from one label to another
Virtually eliminate leakage as a quality issue
Less energy
Convert coiled steel to a finished decorated can in approximately 20 minutes, virtually eliminating work-in-process inventory and maintaining flexibility for our customers
Automation and lean manufacturing techniques reduce the need for untrained personnel, unlike traditional can manufacturing