When the international beverage and liquid food industry meets at drinktec in Munich from 15 to 19 September 2025, ENGEL will demonstrate an automated cell for producing 38 mm closure caps. The fully integrated system centers on an all-electric e-cap 380 injection moulding machine rated at 3,800 kN, running a 48-cavity mould at a four-second cycle. The application targets high output with consistent quality and reduced energy demand. The closures, manufactured for United Caps and conforming to a widely used industry standard, feature a tamper-evident band whose notch is formed in the mould and subsequently folded inward on the underside. When the product is opened for the first time, the band separates from the cap body to provide a clear indication of prior opening. Parts are discharged via a cooling conveyor with waterfall sorting and transferred to a dedicated folding station that bends the lower edge of the band to ensure a secure fit on the bottle neck. Machine, handling and auxiliary functions are coordinated through the CC300 control, and the cell integrates measures for process stability, including a dry air hood over the mould and clamping unit to prevent condensation in air-conditioned environments.
Reliably and efficiently produced slit-and-folded closures: they combine functionality with cost-effectiveness for modern filling processes.
Automated closure production on an all-electric platform
The e-cap series is designed specifically for beverage cap manufacture, combining short cycle times, high part-to-part reproducibility and low energy consumption. All-electric drive technology enables dynamic and precise motion sequences, while a rigid toggle lever provides reliable force transmission. With several clamping-force options and a compact footprint, the machines are intended for continuous operation under demanding production conditions.
As standard, the e-cap is equipped with the ENGEL Packaging package to enhance performance in high-speed packaging applications. This includes a high clamping unit optimised for extremely short cycles, a reinforced elevated moving platen, high-performance machine feet for stable and smooth operation and high-performance injection units. The iQ motion control assistance software automatically optimises mould movements, which helps to reduce cycle times.
All-electric performance with maximum precision and outstanding energy efficiency: the ENGEL e-cap was consistently developed to meet the requirements of closure production.
New injection unit and shut-off nozzle for thin-wall performance
The exhibit features the new 2465 injection unit in its premium version, developed for demanding high-performance applications in thin-wall injection moulding. According to ENGEL, the unit offers an almost 67 percent increase in injection speed. A dosing drive with a screw circumferential speed of up to 1 m/s is used, which is of particular interest in packaging because it enables shorter cycles. The design also emphasises maintainability, with accessible service modules and maintenance points intended to minimise downtime and support overall equipment effectiveness.
In combination with the new rotary slide shut-off nozzle, the injection unit is aimed at applications that require precise control of highly viscous materials at high injection pressure and with short cycles. The robust and precise nozzle design addresses requirements typical of cap production, where short switching times and high flow rates are essential.
Robust, precise, and fast: ENGEL’s new rotary slide shut-off nozzle enables short switching times at high flow rates – ideal for demanding applications such as cap production.
Digital assistance and stable processing conditions
The iQ weight control assistance system analyses the injection process in real time and automatically adjusts the switchover point and holding pressure within a few hundredths of a second. This compensates for fluctuations in shot weight without manual intervention, supporting consistent part quality and low scrap even under tight tolerance specifications.
Additional process reliability is provided by a dry air hood over the mould and clamping unit. By continuously supplying dry air, it prevents condensation from forming on cold surfaces, a benefit in air-conditioned halls.
Cooling control and monitoring with e-flomo one
For the first time, ENGEL will present the e-flomo one cooling water distribution system in this production cell. Developed for applications with high cooling water demand, the control regulates flow rate and temperature difference directly at the main connection of the mould cooling and is fully integrated into the machine control. This enables precise adjustment and continuous monitoring of cooling. By ensuring stable cooling conditions, e-flomo one contributes to scrap reduction, allows targeted optimisation of water volume and automatically compensates seasonal temperature fluctuations to reduce water consumption. In combination with the eco-flomo XL, individual circuit monitoring is also possible.
Closure expertise and trade fair presence
ENGEL is among the manufacturers of injection moulding machines active in closure production, supplying systems for both standard closures and slit-and-folded applications. The company combines a broad machine portfolio with automation and application know-how for the beverage segment.
Visit ENGEL at drinktec, Hall C6, Stand 140.
