At Karmelle, we recognise that every customer faces unique production challenges – and it’s the job of our experienced design team to develop tailored solutions. For cold pressed rapeseed oil producer, Hillfarm, space-efficiency was a priority.
Suffolk-based Hillfarm have been producing and bottling their own cold-pressed rapeseed oil since 2004. In early 2021, the family-run business planned to add two new container-sizes to their product-range. Realising that they would need to invest in new bottle filling equipment, they approached Karmelle for a solution.
Hillfarm’s new system would need to automatically fill, cap and label 2 litre and 5 litre PET bottles. Size and layout were key, as the line would be housed in a 40-foot cube container on Hill Farm.
After discussing Hillfarm’s product and processes, Karmelle were able to offer a bespoke solution; a complete filling, capping and labelling line, comprising a 2 Head Flowmeter Filling Machine, an EK40 Capping Machine, and a Front, Back and Cross Dispense Labeller. The outfeed would also be automated with a Rotary Collection Table.
Taking into consideration Hillfarm’s unique requirements, Karmelle opted to design a new model of flowmeter filling machine for the line. With a servo motor, fewer moving parts and a reduced footprint, this hygienic filler was ideal for the business’ production space. Wide nozzles would allow their viscous products to flow freely. The machine would also be built on a 4 head frame, meaning that extra heads could be added as production increased.
Equipment was manufactured, assembled and tested onsite at Karmelle, before being delivered to Hillfarm. A Karmelle engineer installed the line in their specially-adapted container.
- After the operator selects the correct gate and nozzle setting, empty containers are fed into the filling machine.
- Once filled, containers are automatically transferred to the EK40 capping machine, where caps are screwed on. Each PET container is separated before entering the capper, to prevent crushing.
- Containers that have been filled and capped, travel to the labeller, where front and back labels are automatically applied.
- Containers exit the labeller and pass onto a Rotary Collection Table, ready for packing into boxes.
Hillfarm’s Business Manager Lawrence Frohn explained: “the project presented a challenge, as we needed an end-to-end solution that would fit into our production space. Karmelle met the brief and designing a bespoke system that can be adjusted and modified as production increases.”
To discuss your own filling, capping and labelling requirements, contact our team on +44(0)1484 533356, or email firstname.lastname@example.org.