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Contacts

Headquarter:

Mall + Herlan GmbH

Wöschbacher Straße 33
76327 Pfinztal
Germany

Phone: +49 721 94601 0

 

Mall Herlan MB GmbH

take-off Gewerbepark 143
78579 Neuhausen ob Eck
Germany

Sales Director
 

Siegfried Christ

Phone direct: +49 721 94601 10
Mobile: +49 160 9017 19 54
Fax: +49 721 946 01 99

Sales Manager for Europe, CIS, Russia, Africa and Middle East

Ulrich Gellings

Phone direct: +49 721 94601 123
Mobile: +49 151 5445 01 74
Fax: +49 721 946 01 99

Steel Aerosol Cans

Product lines

More and more brand owners are looking for an alternative to the 2- or 3-piece steel can, to lower the risk of leakages and corrosion. The steel cans produced on our DWI lines are monoblock cans not seamed or welded. Compared to a 2- or 3-piece can the monoblock steel can can be produced with less material and is therefore lighter. The complete production of the steel can is done in one line including the 360° printing and the customized necking and shaping.

DWI Production Lines:

In the DWI customized production line a cup is punched out of a steel sheet, fed by a coil. In the bodymaker the cup is ironed to a cylinder and the bottom is formed. Subsequently the cylinder is cut to length, decorated, necked and shaped to a Steel Aerosol Can.

Hi-Flex DWI200

If you deal with high lot sizes and would like to save material, you should decide for a DWI line. The mall//herlan DWI line is the perfect solution for a flexible and cost-effective production of steel cans out of coiled material.

Packing Machine

Packing Machine

All shapes and sizes of unfilled cans can be palletized on this machine

Special features

  • Ideal for aerosol cans
  • Optimal grouping of cans
  • Simple and quick changeover of form sets
  • Synchronous can transfer
  • High production reliability and security
  • Aerosol cans palletized in bundles or full-layer
Postwasher

Postwasher

In steel can production lines a postwashing machine is obligatory to wash off lubricants after necking. Our customized postwashing machines are equipped with a patented spraying system to ensure low water consumption. A bypass function for the transport without washing/rinsing is included as standard.

Technical data

TypePWM 66
Max. Diameter (mm)66
Chain pitch5 x ¾’’
Number of washing / rinsing cabins2

 

Special features

  • Stainless steel design, cabins equipped with windows
  • Washing of the cans in the first washing/rinsing cabin
  • Rinsing of the cans in the following rinsing cabins
  • All cabins equipped with a patented spraying system with low water consumption
  • Electrically heated tank for the first washing/rinsing cabin equipped with pumps, level control and temperature regulation
  • Dripping area after washing, vertically arranged pins and drying blades
  • Automatic level control of the tanks, equipped with safety unit against water shortage, temperature monitoring unit
  • Stainless steel tank for collecting the dripping water below the washing machine
  • Drying of the cans in the gas heated oven, low-energy design
  • Chain guides made of PTFE (Teflon)
  • Additional blowing nozzles for drying the interior and the rim of the cans/bottles
  • Reliable system for sucking off the oven exhaust air
LD

LD

A photocell is used to detect if rays of light fall into the can through micro-holes. Defective cans are automatically ejected at the outfeed conveyor after the Leak detector. A 100% quality-control ensures that only complete secure cans leave the line. The Leak detector can be placed on the outfeed conveyor of the Necking machine. Alternatively it can be integrated as a stand-alone machine in the line.

Necking machine

Necking machine

The cylinder is necked and shaped by necking dies up to the final can design. Processes as threading, curling, beading, rolling of a gorge to create unique shapes and designs fitting the needs of your customers.

TypeC200.84.
Can diameter (mm)35-66
Finished Product length (mm after necking)110 – 250
Number of stations84
Total stroke (mm)150
Usable stroke (mm)90

Special features:

  • 3 tool carrier plates including can transfer
  • Two special trimming units between tool carrier 1 and 2 and tool carrier 2 and 3, each trimming unit equipped with own drive, swarf suction unit
  • Pneumatic holding grippers with electronic control for can detection guarantee a constant stable position of the can
  • Tool quick-change system for maximum product flexibility
  • Compressed-air assisted necking to enable even complicated shapes
  • Maximum accessibility to the machine working area for easy handling and setting of the tools
  • Optimized can transfer systems between conveyors and drums
  • Electronic presetting device to set lubrication cycles frequency
  • Possible application of all our proprietary tools allowing wide machining possibilities
Accumulator 3

Accumulator 3

for accumulating the cans and compensating the asynchronous operation of decoration unit and necking machine.

Special features:

  • Two-part welded frame, mounted onto the floor with a capacity of 2000 cans
  • Constant chain tension system.
  • Safety covering of the accumulator up to a height of 2,5 m with acrylic glass panes at the front side, rear and top with sheet metal covering. A complete covering of the accumulator is optionally available.
  • Optimized positions of the support drives  
Bottom Spraying station

Bottom Spraying station

Located between over varnish station and corresponding oven the can bottom is coated precisely over its entire area wet in wet. The spray system is synchronized with the transport pin chain and avoiding overspray.

Special features:

  • Cabin for spraying with 2-stage filter system
  • Four spray guns, nozzle sets equipped with precision adjustment
  • Synchronous servo drive for lacquering unit
  • Fan for exhausting lacquer fumes
  • Security doors with electronic door monitoring and door lock, made of safety glass  
Overvarnish

Overvarnish

The overvarnish is applied to protect the decoration. According to the request of your customers also special effects like matt, semi matt, gloss or haptic can be provided. The used Anilox equipment for constant lacquer application consists of an engraved roller, blade and varnish supply unit.

Special features:

  • Can transfer from the conveyor chain to a mechanical take-off drum with size-independent vacuum pockets
  • Mechanical indexing gear unit with 12 stations
  • Mandrel quick change unit and monitoring of the correct clamping
  • Infinitely variable mandrel drive by means of controlled servomotor
  • Vacuum-assisted loading and steadying of the cans on the mandrels, before and during processing
  • Transfer unit with take-off control and two suction units for transporting the cans from the mandrels onto the chain pins
  • Oven chamber with integrated chain guide
  • Sprocket bearings with re-lubricating facility, installed outside the oven in an aluminium casing sealed towards the rear wall of the oven
  • Possibility of can sampling for test purposes from the pins of the dryer chain, after drying of the clear varnish.
Printing machine

Printing machine

The printing unit, which can apply up to 9 colours, ensures the widest possible decoration variety for monoblock cans.

Special features:

  • Can transfer from the conveyor chain to a mechanical take-off drum with size-independent vacuum pockets
  • Mechanical indexing gear unit with 12 stations
  • Mandrel quick change unit and monitoring of the correct clamping
  • Infinitely variable mandrel drive by means of controlled servomotor
  • Vacuum-assisted loading and steadying of the cans on the mandrels, before and during processing
  • Printing unit with up to 9 colours
  • Transfer unit with take-off control and two suction units for transporting the cans from the mandrels onto the chain pins
  • Oven chamber with integrated chain guide
  • Sprocket bearings with re-lubricating facility, installed outside the oven in an aluminium casing sealed towards the rear wall of the oven
  • Possibility of can sampling for test purposes from the pins of the dryer chain, after drying of the printing inks.
Basecoat

Basecoat

The cylinder receives the base coat which is important for the stain resistance and excellent print quality. The used Anilox equipment for constant lacquer application consists of an engraved roller, blade and varnish supply unit.
The base coat is dried in the first oven chamber of the decoration drying oven.

 

Special features

  • Can transfer from the conveyor chain to a mechanical take-off drum with size-independent vacuum pockets
  • Mechanical indexing gear unit with 12 stations
  • Mandrel quick change unit and monitoring of the correct clamping
  • Infinitely variable mandrel drive by means of controlled servomotor
  • Vacuum-assisted loading and steadying of the cans on the mandrels, before and during processing
  • Three roller base-coating unit designed as V-type-coating unit
  • Transfer unit with take-off control and two suction units for transporting the cans from the mandrels onto the chain pins
  • Oven chamber with integrated chain guide
  • Sprocket bearings with re-lubricating facility, installed outside the oven in an aluminium casing sealed towards the rear wall of the oven
  • Possibility of can sampling for test purposes from the pins of the dryer chain, after drying of the basecoat
Accumulator 2

Accumulator 2

for accumulating the cans and compensating the asynchronous operation of internal coating machine and decoration unit.

Special features:

  • Four-part welded frame, mounted onto the floor with a capacity of 3250 cans
  • Constant chain tension system
  • Safety covering of the accumulator up to a height of 2,5 m with acrylic glass panes at the front side, rear and top with sheet metal covering. A complete covering of the accumulator is optionally available.
Internal coat dryer

Internal coat dryer

for polymerizing the internal lacquer coat, electrically heated or alternatively by gas.

Special features:

  • 2 row transport chain with baskets
  • Reduced wear-out of the transport chain and the chain wheels by cardan-based drive system
  • Chain tension with weight, electronically monitored
  • Easy accessibility to the dryer interior due to large doors
  • Quadruple door look
  • Isolated doors with special door hinges for synchronized door closing
  • Large outer doors with smooth surface on the oven’s front- and rear sides
  • Quick and easy removal and reassembly of the shafts and chain wheels in case of service
Internal coating machine

Internal coating machine

A functional lacquer is applied to seal the inside of the cylinder using moveable spray lances. In the following oven with its cooling zone the inside lacquer is cured and hardened.

Special features:

  • Low vibration due to solid mechanical design
  • Individual vacuum circuit for machine infeed and outfeed
  • Increased user comfort by direct electro-pneumatic control of the spray guns by HMI
  • Shorter cleaning times by optimized exhaust performance
  • Height adjustable and horizontally moveable control panel
  • Combinations with different internal coating dryer options (1,2 or 3 rows)
Accumulator 1

Accumulator 1

for accumulating the cans and compensating the asynchronous operation of the washing- and internal coating machine.

Special features:

  • Three-part welded frame, mounted onto the floor with a capacity of 2000 cans
  • Constant chain tension system
  • Connecting traverse at accumulator outfeed to bridge a walkway
  • Safety covering of the accumulator up to a height of 2,5 m with acrylic glass panes at the front side, rear and top with sheet metal covering. A complete covering of the accumulator is optionally available.
Washing machine

Washing machine

After trimming it is necessary to wash the cylinders. With our space-saving washing machines, designed in stainless steel, we offer an economic and energy-saving technology for a perfect washing result.

 

Technical data

TypeCWMx 66-8
Diameter range (mm)45-66  
Chain pitch5 x ¾”
Number of washing / rinsing cabins5

 

Special features

  • Compact, space-saving stainless steel design, washing and rinsing cabins equipped with windows
  • Reliable, adaptable infeed and outfeed system ensuring easy connection to the upstream and downstream machines
  • Safe and reliable infeed and outfeed transfer through vacuum drums
  • Gas or electrically heated stainless-steel drying oven with long dwell time and minimum energy consumption
  • Newly designed jet spray system
  • Detergent dosing by means of conductivity metering and dosing pump
  • Dripping area between wet and dry zone, vertically arranged pins
  • Electrically heated tanks for the degreasing cabins equipped with pumps, level control and temperature control
  • Automatic level control of the tanks, equipped with a safety unit against water shortage and temperature monitoring unit
  • Stainless steel tanks for collecting the dripping water below the machine
  • Reliable system for sucking off the oven exhaust air
  • New extra platform on top of the washing cabins for a better accessibility of the dryer
Trimming machine

Trimming machine

MHB-S

The high-performance trimming machines, designed for trimming steel preforms to length, have been fully equipped to allow flawless integration into automatic production lines. When designing the machine, particular importance was attached to ease of operation, quick tool change, easy access, solid process technology, high operational safety and little maintenance.

 

Technical data

TypeMHB-S
Can diameter (mm)35-66
Max. extruded overall length (mm)275
Max. trimmed can length(mm)260
Assumed wall thickness of cans (mm)0,2 - 0,6

 

Special features:

  • Fully accessible from the front, perfect control of all movements
  • Mechanical indexing gear unit with 12 stations
  • Centralized lubricating system
  • The trimming system produces burrless cuts and guarantees a long tool life, precision adjustment in both axial and radial direction
  • Can scrap will be shredded into small pieces for easy suckoff
  • Equipment for the separation and safe discharge of the trimming scrap
  • Size parts are immediately located in the correct position
  • The drum-type transfer unit makes sure the cans are safely transferred to the downstream equipment
  • Continuously operating conveyor chain at the transfer station
Pre-Accumulator

Pre-Accumulator

for accumulating the cans and compensating the asynchronous operation of the pre-washing machine and trimming machine.

Special features

  • Three-part welded frame, mounted onto the floor with a capacity of 1600 cans
  • Constant chain tension system
  • Connecting traverse at accumulator outfeed to bridge a walkway
  • Safety covering of the accumulator up to height of 2,5 m with acrylic glass panes for the front side, rear and top with sheet metal covering. A complete covering of the accumulator is optionally available.
Pre-Washing Machine

Pre-Washing Machine

The coolant is removed in the pre-washing machine, which is equipped with two washing cabins and three rinsing cabins. The varying dwell time in the rinsing cabins, the patented spray jet system and quality control via conductivity measurement ensure optimum cleaning.

A lot of special features allow as much customization as possible.

Special features 

  • Compact, space-saving stainless steel design, washing- and rinsing cabins equipped with windows
  • Gas or electrically heated stainless-steel drying oven with long dwell time and minimum energy consumption
  • Newly designed jet spray system
  • Dripping area between wet and dry zone, vertically arranged pins
  • Electrically heated tanks for the degreasing cabins equipped with pumps, level control and temperature regulation
  • Automatic level control of the tanks, equipped with a safety unit against water shortage and temperature monitoring unit
  • Stainless steel tanks for collecting the dripping water below the machine
  • Reliable system for sucking off the oven exhaust air
  • New extra platform on top of the washing cabins for a better accessibility of the dryer
Bodymaker

Bodymaker

In a first step the cup is redrawn to its final circumferences. The cylinder is then directly drawn through up to four rings to reduce the wall thickness up to 65% and consequently extend the length (Ironing process). In a last step the bottom of the can formed.

Special features

  • Foundation plate
  • Coolant system
  • Transfer to succeeding mall//herlan prewashing machine
Cupper

Cupper

incl. uncoiler and transfer system

The steel coil is moved from the upender onto the uncoiler. The uncoiled metal is pulled longitudinally into the cupper. The operator can configure the punching process with maximum flexibility to suit the specific requirements by defining the number of active tools and the number and width of the horizontal steps via the control system. A blank holder fixes the material and a circular knife die-cuts a disk. With a subsequent punch the disc is deep-drawn into a cup. A conveyor system transfers cups to the bodymaker.

Special features 

  • Optimized tooling accessibility due to removing the tool by a tool carrier
  • Quick change of die set
  • Flexible number of max. 5 dies possible
  • Optimum utilisation of over 87% of the material
  • No decoupled foundation needed because of vibration absorption between frame and foundation

Markets

Light weight and with a 360° print design, an attractively designed steel can with no seams can be produced on our DWI customizes production line. The complete production of the can including the decoration is done in one process. The line starts with a steel coil and ends with the packing of the cans ready to be filled. Because of the monobloc design without seams the risk of leakages or inner- and outer corrosion is significantly reduced.

The monobloc steel cans are conquering the following markets:

  • Body care
  • Home care
  • Food
  • Technical products

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