Filling and Capping the lightest home care bottle

Project Description

KH Lloreda, manufactures  in Spain a concentrated degreaser specially formulated with European ecological criteria  from a water-based formula free from phosphates, perfume, caustic soda or caustic potash. The company is aware that they are part of the environment  and they work intensely to reduce their activity impact. Reducing, eliminating, recycling and reusing are part of their philosophy.

In 2021 the Trigger Sprayer has been replaced for a new one which is custom designed for KH Lloreda that be re-used 13 times. Additional plastic savings each time the final consumer is purchasing the refill bottle.


What was client's need?

The 750 ml HDPE bottle, which is intended for home care products, has reduced its weight in a 38%, being today the lighest home care bottle of this capacity in the market. With only 28 grams it’s also robust  to hangle and dimensionally stable. Its well-thought-out geometry ensures a particularly a correct material distribution  giving the bottle its necessary pressure resistance.

This also saves on material and improves the CO2 ratio.

When filled, the bottle represents only a 4% of the total weight of the package. The challenge was to be able to orient, fill, cap with a trigger pump and reject nok bottles at 250 u.p.m. without damaging any bottle.

How did Mengibar solve it?

Mengibar MassFlow and MagFlow Filling Heads don’t lean on the bottle or even enter in contact with the bottle neck. Filler central starwheel keep the neck in position with individual clamps and the bottle doesn’t support any force that can make it collapse.

The Capping starwheel was specifically designed to keep the shape of the bottle even when the Capping Head is pressing the trigger pump down. HDPE bottles do not have any supporting ring like PET bottles, so the advanced design of this starwheel was the key of the success of the project.

KH LLoreda saved a few grams per bottle, just make a quick calculation considering how many millions of bottles are filled each year.

We invite you to watch the following video where we explain in more detail how we solved the case study.