Complex highspeed closure production
Additive, sealing and design
In the highly competitive beverage packaging market, speed, reliability and flexibility are decisive factors. Contexo assembly machines operate at a pace so high that in six-hundredth of a second, a new closure is assembled, folded, inspected multiple times and transferred downstream. This corresponds to up to 920 closures per minute and more than 1.3 million parts per day.
This performance level is the result of a clear technological decision: continuous-motion rotary assembly. Contexo has been investing in this principle for 25 years now and has continuously developed it further to meet the increasing demands of the market. The assembly machines run in a constant, synchronised flow. The company says that this reduces dynamic loads, minimises wear and allows higher output rates without compromising part quality or machine stability.
At the heart of the system is a central rotary tower equipped with up to 36 processing tools. These tools perform all assembly and forming operations while the closures remain in continuous motion. Feeder satellites supply the individual components at a precisely controlled speed and orientation, ensuring timing and gentle handling of the parts. Especially for warm-moulded plastic components, this controlled transfer is critical. By avoiding abrupt acceleration or deceleration, material stress is minimised and dimensional accuracy is maintained throughout the process.
Inline inspection
Inline quality assurance is another key element of Contexo’s approach. Each closure is inspected several times during assembly using integrated inspection systems. Defects are detected immediately, preventing faulty parts from progressing through the line. This direct inline inspection is a key factor in achieving the company’s objective of reliable production.
“The challenge was to build an exceptionally reliable and fast assembly machine within a very small footprint,” explains Matthias Müller, Chief Commercial Officer of Contexo. “From our experience, continuous motion combined with feeders for warm-moulded parts and direct inline inspection is the most effective solution. It allows us to push output limits while maintaining full process control.”
High-speed production
When Contexo began developing continuous-motion systems output rates of around 300 parts per minute were considered state of the art. Today, Contexo machines operate at three to four times that speed. Continuous motion has proven to be a robust foundation for long production runs, reduced maintenance intervals and stable process conditions.
Flexible design
Beyond sheer speed, Contexo has developed expertise in the field of complex beverage closures. Modern closures increasingly integrate additional functions that go beyond simple sealing. These include the integration of additives such as powders, pills or liquids; tamper-evident features; printing and marking; as well as laser-based cutting and welding processes. Each of these functions adds complexity to the closure design and, consequently, to the assembly process.
The company’s systems combine multiple process steps into a single, compact machine with high output rates. Laser cutting for tamper-evident functions, for example, is integrated directly into the rotary process, as are laser welding and high-precision printing operations. This integration reduces handling steps and shortens cycle times.
Market dynamics further increase the demands placed on closure manufacturers. Complex closures are frequently introduced together with new beverage products as a means of differentiation and added value. If such a product is successful, demand for the corresponding closure can rise sharply within a short period of time. Assembly systems must therefore be able to scale quickly, without long downtimes or costly reinvestments.
Sustainable tooling
Contexo has developed a modular platform concept. This platform is designed to cover a wide range of output rates and product variants within a unified machine architecture. Modules, stations and tools can be added, removed or reconfigured to adapt to changing production volumes or new closure designs. This flexibility allows customers to respond rapidly to market developments.
An important aspect of the modular platform is its ability to support the entire product life cycle. During market introduction, lower output rates may be sufficient. As demand grows, the same platform can be expanded to higher capacities. Later, when a product reaches maturity or is replaced, existing stations and tools can be transferred to new machines or adapted for new applications. This reuse of proven components reduces costs, shortens project timelines and ensures consistent quality across generations of equipment.
In an environment where many manufacturers present new machines and technologies side by side, Contexo focuses on continuous-motion technology combined with established process expertise and a modular system design. High production speed, low defect rates and flexibility are treated not as isolated features, but as integral elements of a consistent engineering approach.