Keraplast Manufacturing successfully integrated a new filling system with their existing rotary table, achieving precise, air-free filling of medical gel into aluminium tubes. The final solution met the customer's expectations, seamlessly blending new technology with existing equipment.

The Challenge

Keraplast Manufacturing in Christchurch faced several unique challenges:

• Filling medical gel into two different sizes of aluminium tubes
• Integrating a new filling system with an existing rotary table used for crimping
• Preventing air entrapment in the product during the filling process
• Incorporating a reliable tube detection system
• Ensuring compatibility between new and existing equipment

The Solution

Hunter Filling Systems provided a customised, precision-engineered solution:

Specialised Filling Machine:

• Designed and manufactured a Hunter Model 205 Filler
• Incorporated a diving nozzle mechanism for air-free filling

Custom Integration:

• Tailored the new filler to work with the existing rotary index table
• Underwent multiple iterations to perfect the integration process

Air-Free Filling Technology:

• Implemented a diving nozzle system to prevent air entrapment during filling
• Ensured product integrity by avoiding bubbles in the medical gel

Smart Detection System:

• Incorporated signals to detect the presence of tubes
• Enhanced operational safety and efficiency

Versatile Design:

• Capable of handling two different sizes of aluminium tubes
• Maintained flexibility in production capabilities

Through persistent refinement and attention to detail, Hunter Filling Systems successfully integrated the new filling technology with Keraplast's existing equipment. This meticulous approach ensured that the final solution precisely met the customer's unique requirements for their medical gel product.