NOZZLES
Also called chuck or die, the nozzle is a component used for capping bottles with various types of closures in the bottling industry. These parts are mostly made from 304 stainless steel and naturally wear down over time. Currently, they are categorized into three system types: Pick and Place, Pick Off, and Manual.
Capping nozzles are mainly characterized by the compatibility between the number of teeth on the nozzle and the cap. For example, if a 28 mm cap has 120 teeth, the nozzle will be made with 60 teeth to ensure a perfect fit between nozzle and cap.
The Pick and Place system is how modern machines are designed. In this system, the capping nozzle picks up the cap and brings it to the bottle to perform the capping, applying the correct torque through a magnetic head.
Pick and Place nozzles must have balls or spherical pins to carry the caps to the bottle. For 26 mm, 28 mm, and 38 mm caps, typically 6 spherical pins are used, mounted with an O-ring made from a material suited for each specific use.
The Pick Off system is found in older capping machines, usually over 20 years old. In this system, the bottle picks up the cap from a chute. Also known as the “Fisherman System,” it may use a pre-torque system and a cap positioning plate. Torque is applied by the nozzle along with the magnetic head.
Pick Off nozzles do not have transport pins or balls. These nozzles only have internal teeth. At the top, they are equipped with a hammer system and springs to properly square the cap with appropriate pressure for the system to function.
In a manual system, capping is done using a threader, a screwdriver, or even by hand, depending on the production size.
A manual nozzle may include a hex Allen coupling to connect it to the equipment. For hand-operated closures, an aluminum or polyacetal handle is used, with an internal part made from 304 stainless steel.
That is a myth. The nozzle is a machined stainless steel part with pre-defined dimensions, just like the cap, which has fixed rigidity and doesn’t change during filling. Therefore, it is not possible to machine a nozzle to fit multiple caps. Each nozzle is precisely machined according to each cap’s brand/model. However, since caps can have manufacturing tolerances (around +/- 0.2 mm), Dóni-Tec nozzles accommodate those tolerances. Sometimes, caps from two different suppliers may have identical specs, in which case a single nozzle may be compatible with both.
There’s no exact formula to estimate nozzle life. It depends on factors like cap model, cap material, machine geometry, machine speed, etc. Machines in poor condition tend to wear out nozzles faster, averaging 6 months. Normally, it’s around 1 year, and in well-maintained machines, nozzles can last up to 2 years.
There’s no exact formula to estimate nozzle life. It depends on factors like cap model, cap material, machine geometry, machine speed, etc. Machines in poor condition tend to wear out nozzles faster, averaging 6 months. Normally, it’s around 1 year, and in well-maintained machines, nozzles can last up to 2 years.
It’s recommended to replace the O-ring every 3 months. Although made of specific rubber for the application, external factors like ozone or cleaning chemicals degrade it. Once degraded, application issues begin. Pins should be visually inspected and usually replaced every 6 months due to wear.
Even if all caps are labeled 28 mm, each supplier and mold introduces variables that require a specific nozzle for each cap. These include tooth design, cap height differences, dimensional variation (beyond what the nozzle can handle), cap material, etc.
We always produce nozzles based on physical cap samples. The technical drawing is only used as a reference for quoting. All parts are manufactured using the physical sample of the product to be applied.
INSERTS
Dóni-Tec sources raw material directly from Europe to manufacture anti-slip inserts. This specific material, after vacuum oven heat treatment, becomes corrosion-resistant and can be polished for improved durability and hygiene in the bottling line.
No. All Dóni-Tec parts are CNC machined. Inserts are fully machined, and their teeth are ground one by one using a surface grinder for precise dimensions and sharpness.
It holds the bottle in place during capping. Fixed by 2 or 3 screws, the inserts have teeth on the top that grip the bottle during capping. They are hardened components, undergoing a heat treatment process for increased wear resistance.
As with nozzles, there’s no precise formula to determine lifespan. It depends on factors like machine setup, geometry, and speed. Machines in poor condition cause inserts to wear faster.
When the teeth on the insert are worn or damaged, the bottle isn’t held securely and may rotate with the cap during capping. In some cases, a damaged insert can scratch the bottle, leaving burrs or defects that can injure the consumer.
If it’s your first time buying our products, we will need a sample so we can design the insert according to the machine fit. It’s also necessary to identify the preform being used in your bottling line.
GAUGES
Gauges are used to check if caps or preforms comply with the specifications and standards set by suppliers.
This piece is usually machined from a 304 stainless steel plate, with holes and/or pins for minimum (go) and maximum (no-go) dimensions, making it quick and easy for the quality inspector to verify dimensions.
You’ll need to provide the minimum (go) and maximum (no-go) dimensions. If you don’t have these, ask your supplier for a technical drawing with the dimensions. Some sizes are standardized, like for pry-off and twist-off metal caps.
GONIOMETERS
Used to check the application angle of caps, goniometers (or degree protractors) are made of 304 stainless steel.
t’s a ring with a high-quality adhesive label showing angle markings, usually in different colors like green, yellow, and red. Laser engraving can also be used instead of a label.
You need to provide the application angles, which you can obtain from your cap supplier.
Male tips have external teeth and simulate the cap, used to measure torque on the machine. Female tips simulate the nozzle, with internal teeth, and are used to measure torque on the applied cap.
