From Chaos to Control: The Multi-SKU Capping Challenge

Jim Karatasos

The Reality on Today’s Factory Floors

When Filling Is Automated but Capping Isn’t

It’s a familiar scene across many Australian manufacturing sites: bottles gliding smoothly through an automated filling system, only to reach a section of the line where chaos takes over. Two operators rush to place pumps and caps onto bottles before the conveyor carries them away — racing against automation itself.

Despite advances in Capping Machines, many production lines still rely on manual or semi-manual capping because automating the process for diverse products has long been a challenge.

Manual Pump Placement — the Hidden Bottleneck

While filling and labelling systems have evolved dramatically, capping remains one of the most labour-intensive stages of production. Placing pumps or caps by hand introduces fatigue, inconsistency, and inefficiency. It also becomes a major constraint on throughput, making it difficult to scale production or maintain quality at higher speeds.

Why Multi-SKU Lines Are the Hardest to Automate

Manufacturers handling a wide variety of products — from flip-top bottles to trigger sprays and screw caps — face constant changeovers. Each closure type requires different handling, feeding, and torque settings. Traditional automation systems were never designed to handle this diversity. As a result, many businesses automate filling but stop short of full end-of-line automation because capping seems “too hard.”

Understanding the Capping Challenge

The Complexity of Caps, Pumps, and Closures

Not all caps are created equal. Pumps and triggers arrive in awkward shapes and orientations, caps vary in size and texture, and bottles differ in height and geometry. Feeding, orienting, and presenting these components to a capping head is one of the toughest mechanical problems in packaging automation.

Why Traditional Capping Machines Struggle with Variation

Most conventional Capping Machines are built for repeatable, single-format operations. They rely on dedicated tooling and fixed-pitch feeders that work beautifully for one closure type — but fail when product variety increases. Every new SKU can mean mechanical changes, lost time, and the need for a specialist to recalibrate.

The Gap Between Filling Automation and True End-of-Line Control

Filling machines are flexible by nature; capping traditionally hasn’t been. The result is a semi-automated line where efficiency breaks down at the final step. This gap between automated filling and manual capping is where most productivity losses occur — until now.

How Flexible Capping Machines Change the Game

Automating Cap Feeding and Presentation

The biggest hurdle in automating capping has always been feeding and singulating pumps, caps, and closures. Process Evolution’s flexible Capping Machines eliminate this barrier. Using intelligent mechanical and vision-based systems, they can automatically detect, orient, and feed multiple closure types without manual assistance.

Intelligent Capping Head Design for Multiple Closures

Our systems are engineered with adaptive torque heads and servo-driven movements that adjust to each closure type and bottle height. Whether it’s a screw cap, pump, or trigger sprayer, the same system can handle it — all controlled through digital recipes.

From Pre-Placed to Fully Automated — Closing the Loop

In many factories today, operators still pre-place pumps for automated torqueing. With a flexible capping system, even this final manual step can be eliminated. By fully automating feeding, placement, and tightening, you achieve a truly end-to-end automated line that doesn’t rely on human intervention.

Key Features of a Modern Flexible Capping Machine

Adaptive Handling for Diverse Products and Cap Types

Our machines use servo-controlled axes and intelligent sensing to recognise different product dimensions and cap styles. They automatically adjust grip strength, positioning, and torque profiles — maintaining precision regardless of variation.

Servo-Controlled Torque and Height Adjustment

Consistent torque is essential for seal integrity and product safety. Our Capping Machines apply precise, programmable torque for each product recipe, ensuring every cap is secure without over-tightening.

Recipe-Based Programming for Fast Changeovers

Operators can select stored recipes from the HMI, instantly recalling parameters for cap type, bottle height, and torque setting. What once took hours can now be done in minutes — no tools, no downtime, and no stress.

The Benefits of Automating Your Capping Process

Consistent Torque and Reliable Seal Integrity

Automation eliminates the variability of manual capping. Each closure is applied with perfect accuracy, ensuring consistent product quality, improved shelf life, and reduced rework.

Reduced Labour and Improved Line Efficiency

Automated capping removes the need for multiple operators at the end of the line. Labour resources can be redirected to higher-value tasks such as quality assurance or logistics, while throughput increases significantly.

Seamless Integration with Filling and Labelling Equipment

Process Evolution’s Capping Machines integrate seamlessly with upstream fillers and downstream labellers or case packers. This creates a continuous, balanced production flow that maximises efficiency across the entire packaging line.

Designed and Supported Locally for Australian Manufacturers

Built to Handle the Diverse Needs of Contract Manufacturing

Our equipment is purpose-built for contract manufacturers and brand owners managing a wide product mix. Whether you run 10 SKUs or 100, our systems handle fast changeovers, small batches, and high-mix production with ease.

Local Design, Engineering, and Service Expertise

As an Australian company, we understand the challenges faced by local manufacturers — from smaller batch runs to short lead times and high compliance standards. All Process Evolution systems are designed and supported locally, with on-site commissioning and training available nationwide.

Reliable Support and Spare Parts from an Australian Team

When you invest in automation, support matters. Our local engineers provide responsive service, spare parts availability, and long-term maintenance partnerships to keep your Capping Machines running at peak performance.

From Manual Chaos to Automated Control

Real-World Results from Flexible Capping Automation

Factories that once relied on operators manually feeding pumps and caps are now achieving full automation with consistent, reliable performance. The results: fewer rejects, faster throughput, and happier teams.

Future-Proofing Your Line for Growth and SKU Expansion

As your product range grows, your capping system grows with you. The modular design of our Capping Machines allows for future upgrades, additional tooling, and software features without replacing the core machine.

The Process Evolution Advantage

For over two decades, Process Evolution has helped Australian manufacturers bridge the gap between concept and capability. Our flexible capping technology turns production bottlenecks into opportunities — enabling true chaos-to-control transformation at the end of the line.

Conclusion: From Chaos to Control with Flexible Capping Machines

The capping process has long been the toughest automation challenge in multi-SKU environments — until now. With Process Evolution’s flexible Capping Machines, manufacturers can finally automate the most unpredictable part of their line, achieving consistent quality, faster changeovers, and reliable performance across every product.

If your team is still manually placing pumps or caps at the end of a fully automated filling system, it’s time to make the leap from chaos to control.

Contact Process Evolution today to learn how our Capping Machines can streamline your production line and future-proof your business.