Why Aluminium Foil

To use a foil cap, what else is needed?
A capping press typically operates as part of a rotary filling system that enables caps to be applied to the container, using a chute that transports the caps from the tools where the cap is made, to the point of cap application.

Whilst rotary fillers are the most common method, in-line linear indexing fillers can also accommodate a capping press.

An aluminium cap is normally round and in standard format can be made in diameters up to 88mm and at speeds of up to 660 caps per minute. Caps are often made with a tab for ease of opening and for single-serve products, a tab should be considered essential.

Aluminium capping presses are built to the exact specifications required for perfect capping on a specific container. When a range of containers must be filled and capped on the same line, it is normal for common neck dimensions to be specified.

An aluminium cap must be heat-sealed in place and the ACS Linear Belt Sealer provides a unique and extremely cost-effective sealing system, utilising the latest in induction technology.

	Why Use Aluminium Foil Caps ?
	Product integrity The foil cap was originally developed as a seal for bottled dairy products in the UK. For many years since, it has been the only method of ensuring total product integrity and extended shelf life in a range of applications, particularly liquid dairy and juice products. A product that is to be in-bottle sterilised should always be capped and heat-sealed by an aluminium foil cap before sterilisation. The hermetic seal provided by the foil cap ensures total integrity and gives flexibility in the choice of screw caps which are applied downstream of the steriliser or retort. The development of Aseptic and ESL (extended shelf life) processing has dramatically changed the worldwide demand for foil caps. Product integrity is particularly critical in Aseptic and ESL filling systems and aluminium foil caps continue to be regarded as the essential closure for providing a hermetic seal and tamper evidence, trusted by both producers and consumers. In the modern world, where safety is such a major concern, the confidence that an aluminium foil cap will provide cannot be underestimated. The foil cap is applied and sealed to the container before it leaves the enclosed filler chamber, giving the highest levels of protection, with downstream screw capping if required. Laminated foils ensure perfect heat-sealing across a wide range of containers, including HDPE, PET and glass. HDPE containers, which are less expensive than PET, must always use a foil cap, due to the normal surface variations in a blow-moulded bottle. Foil caps are used in aseptic, ESL and short shelf-life filling systems as well as for hot-filled products and those to be in-bottle sterilised.
	Product Image Modern laminated aluminium foils are designed specifically for use with a capping press and they can be pre-printed with an all-over colour, a brand logo or embossed with a logo at the point of cap making. Because the foil cap is made as a 3-dimensional object, it will fit perfectly over the container without any distortion and gives a high quality finish that is far superior to a flat diaphragm that is crimped to shape after application. As a result, a foil cap formed on an aluminium capping press is the only cap-less seal that has a finish which is good enough for retail sale in single units. The marketing benefits of a superior image should not be underestimated and when combined with the low unit cost of a foil cap, it is a unique business opportunity. The fast-expanding market for single-serve drinking yoghurt and probiotic drinks has also fuelled the demand for foil caps proving that the well-designed foil cap, with perhaps an all-over print, can impart the quality image that a global brand must have.
	Packaging cost The financial argument for a foil cap is based on its very low unit cost compared to an over-cap. This differential is even greater when compared to the cost of an over-cap with a wadded diaphragm. Aluminium foil caps are produced online from foil reels by the capping press, also eliminating cap stockholdings, extra handling and sorting equipment. The increasing cost of oil has impacted on plastics prices and this only increases the savings that can be made by eliminating over-caps.
	To use a foil cap, what else is needed? A capping press typically operates as part of a rotary filling system that enables caps to be applied to the container, using a chute that transports the caps from the tools where the cap is made, to the point of cap application. Whilst rotary fillers are the most common method, in-line linear indexing fillers can also accommodate a capping press. An aluminium cap is normally round and in standard format can be made in diameters up to 88mm and at speeds of up to 660 caps per minute. Caps are often made with a tab for ease of opening and for single-serve products, a tab should be considered essential. Aluminium capping presses are built to the exact specifications required for perfect capping on a specific container. When a range of containers must be filled and capped on the same line, it is normal for common neck dimensions to be specified. An aluminium cap must be heat-sealed in place and the ACS Linear Belt Sealer provides a unique and extremely cost-effective sealing system, utilising the latest in induction technology.
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