Karmelle Liquid Filling & Capping Solutions Limited

Case Studies

Blackwater Distillery: 1 litre filling machine and labelling system. 

The brief:

West Waterford’s Blackwater Distillery approached Karmelle in 2016. With demand for its award-winning Irish gin growing, the brand needed to invest in both filling and labelling equipment.

The solution:

The Karmelle team designed, built and installed a 4 head 1 litre filler, and a Front and Back 3 Point Wrap and Neck labelling system – both of which were capable of handling Blackwater’s round and rectangular glass bottles.

The system applied body and neck labels to each bottle, before top-filling them with gin.

This bespoke equipment has enabled Blackwater to meet the growing demand for its product. The brand has since built a new micro-distillery, and is preparing to add a new Irish whisky to its range.

 

Yorvale:  Filling, capping and labelling line.

The brief:

Award winning ice cream brand Yorvale tasked Karmelle with designing and building a bespoke system to fill, cap and label its natural kefir drink, Yorlife.

Yorvale has been producing real dairy ice cream on its farm, Fossfield, for almost 30 years – and approached Karmelle after adding kefir to its product range.

The brand needed hygienic, quick-strip equipment, capable of filling, capping and labelling 230ml and 500ml bottles.

The solution:

Karmelle’s team designed and manufactured a complete line, comprising an air rinser, Flow Meter Filling Machine, 3 Head Rotary Screw Capping Machine and collection table.

The equipment was installed in a custom built production room on Fossfield Farm, and is currently running at speeds of 44 bottles-per-minute (230ml bottles) and 28 bottles-per-minute (500ml bottles).

Yorvale said: ‘We chose Karmelle because of its reputation for both high-quality machinery and excellent after-care. The equipment has enabled us to bring our latest product, Kerlife, to market.’

 

Glastonbury Spring water: Rotary Monoblock filler and capper with labelling machine. 

The brief:

In 2010, Glastonbury Spring Water commissioned Karmelle to design and build a complete bottling line for its natural spring water. The company needed to sympathetically fill, cap and label its water (which is drawn from a spring below the famous Glastonbury Tor), and was keen to source British-made equipment.

The Solution:

Brian and his team designed a Rotary Monoblock filler, which automatically fed bottles onto a production line, before washing, filling, capping and labelling them.

Glastonbury  specified a machine capable of filling 330ml bottles of still or carbonated spring water at a rate of 40 per-minute.

Under tests, this complete filling line proved capable of running at 80 per minute.

 

Quat-Chem: Turnkey filling, capping and labelling line.

The brief:

UK-based chemical company Quat-Chem required filling, capping and labelling equipment to package its biocidal raw materials and disinfectants.

The solution:

After securing the contract, Karmelle Ltd designed, built and installed a turnkey filling, capping and labelling line for the specialist chemical manufacturer.

The system featured a fully automatic in-line Volumetric Filling Machine, built on a four-head modular frame, and suitable for a wide range of products – including oils and chemicals.

Once filled, bottles were passed onto a single-head EK40 Inline Pick-and-Place Screw/Push Capping Machine.

Finally, a Servo S2-175 labelling machine applied labels to Quat-Chem’s containers.

Contracting Karmelle enabled Quat-Chem to single-source all its packaging machinery, rather than engaging a number of different suppliers.

 

Sidalco: Complete filling line.

The brief:

Karmelle Ltd was chosen by African firm Sidalco (based in Tema, Ghana) to export three automated processing lines. These production lines would need to fill, seal and label plastic containers of the company’s branded agrochemical, Defender.

The solution:

Karmelle designed and built the filling, sealing and labelling lines in just 16 weeks. Its engineers travelled to Ghana to commission the plant and train local workers to operate it.

The  equipment allows Sidalco to produce up to 20,000 litres of fungicide a day. This product is used to protect a range of agricultural and horticultural crops in copper-deficient soil.