No realignment needed after changeovers, saving thousands in can wastage
Switching to HandyCoat™ can save beverage can plants up to 200 wasted cans each week, along with multiple litres of primer and varnish. These savings are realized due to the set-up of the HandyCoat™ system, which features the HandyBase coater core and removable HandySleeve coater coverings.
Unlike conventional wheels and crowns, the HandyBase coater core is not removed during changeovers. Only the HandySleeve coater covering is removed. This means that the wheel does not have to be realigned after a changeover, significantly reducing can wastage.
With a conventional wheel, multiple checks are required following a changeover and realignment. With each check, 20 – 25 cans may be wasted, and this may be repeated several times per changeover. This wastage adds up. Let’s look at the potential numbers, for a plant with three lines:
Conventional wheels – estimated can wastage
Cans wasted per changeover – 75 per alignment check, x 3 alignment checks per changeover = 225 cans per month, for a single line.
For three lines: 14 Changeovers/line/year x 225 X 3 lines = 9,000 to 10,000 cans /year.
To compare, let’s look at the wastage numbers for HandyCoat™. Because the wheel does not have to be realigned after a changeover, and this after changing the HandySleeve, the full production rate is resumed very quickly.
HandyCoat™ – estimated can wastage
Cans wasted per changeover – 3 to 5 per alignment check, x 1 alignment check per changeover = 3 to 5 cans per month (due to longer lifetime of the Monkal coater covering), for a single line.
For three lines: 11 Changeovers/line/year x 4 x 3 lines = 100 to 150 cans /year.
In addition, thanks to the Monkal polyurethane which coats the HandySleeves, coating wastage (drips and spray onto the decorator in the area surrounding the wheel) are greatly reduced. The unique characteristics of Monkal mean that the primer or varnish transfers very easily and quickly from the covering to the can, so less coating is needed (or wasted).