How automated cap assembly works (without sensors)

1) Cap feeding

Caps are poured into a feeder that orients and singles them with track tooling and escapements. Most projects use a vibratory bowl feeder or a rotary feeder set, depending on target rate and cap geometry. For heavy or scuff-sensitive caps, an aluminium bowl feeder adds stiffness and durability. Tracks deliver one clean lane to the pick point—no electronics, just stable mechanics.

2) Container handling

Bottles are spaced by conveyor guides or a compact rotary indexing table. Starwheels and neck guides hold each bottle so the capper sees one position at a time. This stable presentation keeps torque repeatable and rejects low. If you’re new to indexers, see these primers: Guide to Rotary Index Tables and How to Select a Rotary Indexing Table.

3) Cap placement

A pick-and-place arm or mechanical placer sets the cap onto the neck. Motion is tuned so threads catch smoothly. For snap caps, a controlled press hits a fixed depth. Mechanical hard stops and positive locators keep the movement repeatable, cycle after cycle.

4) Cap sealing

The cap is tightened or pressed to spec using:

• Screw capping with clutch or servo heads for threaded closures
• Press/snap capping for push-fit lids
• Magnetic or mechanical torque control to avoid over-tightening

Quick primer on machine types: Capping Machines Overview.

5) Inline checks (mechanical, not electronic)

Instead of sensors, we rely on mechanical gauging at the pick and seat points (hard stops, depth collars) and the capper’s native torque control. Outliers divert to a reject lane. For traceability, teams often log periodic manual torque checks with a handheld tester—see A Guide to Bottle Cap Torque Testers, plus practical ranges in Torque Guidelines & Measurement and the
SKS Torque Guide.

6) Fast changeovers

Change parts (chucks, guides, starwheels) swap quickly. Load the correct recipe in the capper (speed/torque setpoints) and you’re back in production—no re-teaching cameras or thresholds.

Why automate your capping (the sensor-free way)

• Higher output: Machines cap faster and keep a steady beat.
• Better consistency: Same placement and torque across shifts.
• Lower labour: Operators supervise, not twist caps.
• Fewer jams: Tooling, hard stops, and lane control prevent pile-ups.
• Safer work: Less repetitive strain and fewer pinch points.
• Flexible: One setup runs several cap sizes with quick change parts.
• Scalable: Add lanes or speed without adding headcount.

TNC Technology’s approach

Tooling that does the work

We design tracks, nests, and escapements that flow smoothly without electronics. Clean bends, proper back-pressure, and simple gates keep caps moving.

Neat integration

Pick point, mounts, and I/O come ready to tie into your PLC, robot, and capper—no sensor mapping needed. Service access is open and labelled for quick PM.

Built for Malaysian manufacturing

From personal care and F&B to household and electronics, we support local and export lines. Explore:

• Bowl Feeder vs Rotary Feeder: Which is Best?
• Best Bowl Feeder Supplier in Malaysia
• The Future of Rotary Feeders

Common configurations we support

• Single-head torque capping for small batches or frequent changeovers
• Multi-head rotary capping for higher speeds and long runs
• Press capping for snap and push-fit lids
• Options for child-resistant and tamper-evident closures

Practical setup tips

• Use real production samples to tune bowls, tracks, and capper torque.
• Keep cap edges and liners clean—burrs and dents invite jams.
• Save torque settings by SKU (bottle thread + liner affect torque).
• Add a simple mechanical high-level gate before pick to prevent pile-ups.
• Match closures to finishes correctly: see bottle neck finishes & thread sizes (e.g., 28–400, 20–410) in this guide:
  Bottle Neck Finishes & Dimensions.
• Regulated markets: for tamper-evident rules on OTC drugs, check 21 CFR 211.132; for child-resistant packaging, see ISO 8317 overview.

FAQ:

What caps can you run?

Screw, snap, press-fit, child-resistant, and tamper-evident. We tune feeders and tooling to your caps and bottles.

How fast can it go?

Depends on cap size, bottle stability, and torque spec. Share your target rate and we’ll size the feeder and capper to hit it.

Do you use cameras or sensors?

No. Our standard cap assembly solutions are sensor-free and rely on robust mechanics and the capper’s built-in torque control.

How long is a changeover?

Usually minutes—swap chucks and guides, load the recipe, and run.

Do you support projects outside Malaysia?

Yes. We build in Penang and support regional and international lines. Start here:
Contact TNC Technology.