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MANUFACTURING PROCESSES
1.1 Aluminium Can
Our two–piece beverage can is produced in a continuous process, which converts aluminium into
cans. The process incorporates metal-forming, cleaning, internal and external treating and coating,
and the application of final decoration.

Aluminium Can Manufacturing process – Step by Step

Step 1
Aluminium coils are received at our plants in preparation for
the manufacturing process.

Step 2
The aluminium coil is cut into strips. The strip is lubricated
with a thin film of oil and then fed continuously through a
cupping press which blanks and draws thousands of
shallow cups every minute.

Step 3
Each cup is punched through a series of tungsten carbide
rings. This is the drawing and ironing process which
redraws and literally thins and lengthens the walls of the
cans into its final can shape.

Step 4
Trimmers remove the surplus irregular edge and cut each
can to a specific height. The surplus material is collected
and recycled.

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Step 5
The trimmed can bodies are passed through highly efficient
washers and then dried. This removes all traces of oil in
preparation of the internal and external coating.

Step 6
The clean cans may be base coated externally with a clear
or pigment base coat which forms a good surface for the
printing inks.

Step 7
The cans pass through a hot air oven to dry the coating.

Step 8
The next step is a highly sophisticated printer/decorator
which applies the printed design - up to six colours, plus a
varnish.

Step 9
A coat of varnish is also applied to the base of each can by
a rim-coater.

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Step 10
The cans pass through a second oven which dries the inks
and varnish.

Step 11
The inside of each can is sprayed with lacquer. This special
layer is to protect the can from corrosion and its contents
from any possibility of interaction with the metal.

Step 12
Internal and external lacquered surfaces has already been
dried in an oven.

Step 13
The cans are passed through a necker/flanger. Here the
diameter of the wall is reduced or 'necked-in'. The top of
the can is flanged outwards to accept the end once the can
has been filled.

Step 14
Every can is tested at each stage of manufacture. At the
final stage it passes through a light tester which
automatically rejects any cans with pinholes or fractures.

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1.2 Aluminium Can End
The can end process incorporates stamping aluminium, application of sealing compound and
conversion into a finished end.

Aluminium Can End manufacturing process – Step by Step

Step 1
Can end manufacture begins with a coil of special alloy
aluminium sheet.

Step 2
The sheet is fed through a press which stamps out
thousands of ends every minute.

Step 3
As the ends are stamped out the edges are curled at the
same time.

Step 4
The newly formed ends are passed through a lining
machine which applies a very precise bead of compound
sealant around the inside of the curl..

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Step 5
A video inspection system checks the ends to ensure they
are perfect.

Step 6
The pull tabs are made from a narrow width coil of
aluminium. The strip is first pierced and cut and the tab is
formed in two further stages before being joined to the can
end.

Step 7
The ends pass through a series of dies which score them
and attach the tabs, which are fed in from a separate
source.

Step 8
The final product is the retained ring pull end.

Step 9
The finished ends, ready for capping the filled cans, are
packaged in paper sleeves and palletised for shipment to
the can filler.

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1.3 PET Bottle
VisyPak Beverages manufactures PET bottles and jars. Our primary manufacturing process is
referred to as two-stage PET. Simply put, there are 2 steps in the manufacture of the PET bottle:
• Creation of the Preform
• Blowing the Bottle

PET Bottle Manufacturing process – Step by Step

Creation of the Preform
A preform is the first stage of bottle production and is
the result of the Injection Moulding process.
Each preform is shaped like a test tube with the upper
end in the shape of the bottle mouth (the finish).
This preform is thick, round and comes in many sizes
depending on the required final bottle size.

Step 1
A vacuum draws mixed virgin and reformed pellets into
the drier. The resin is dried to below a moisture content
of 50ppm (particulates per million).

Step 2
After several hours, the blended resin is injected
into the preform mould and clamped, resulting in
the production of the embryonic bottle.

Blowing the Bottle

The next and final manufacturing stage is called Blow Moulding. The blow moulding machine
creates the final shape of the bottle.
Step 3
The preform is heated by ‘heater boxes’ with several
variable lamps. The settings of these lamps is called
the profile.

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Step 4
The preform is transported into the mould. A hot preform is
clamped in a blow

Step 5
A stretch rod enters the preform and stretches it lengthwise.

Step 6
Low pressure air is blown into the preform to form the main
part of the bottle.

Step 7
High pressure air is blown into the bottle to fill out the details like
the feet and any markings (e.g. logos)

Step 8
The air is allowed to escape from the bottle and this time in
contact with the chilled mould allows the bottle to crystallise.
Time is allotted in the cycle to depressurize the mould before
opening it and removing the bottle.

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1.4 Carton Manufacturing Process
Combibloc Manufacturing process
Combibloc cartons are printed, laminated, cut and creased, folded and longitudinal seam sealed at the
VisyPak manufacturing site located at Broadmeadows, Victoria.
Before entering the CombiBloc filler the packs are called “sleeves”, it is only after they are formed and
filled they are called cartons.
The sleeves are produced from multilayer laminate of paperboard, aluminium foil and low density
polyethylene. A variety of high and low acid products can be filled into the CombiBloc carton.

THE PROCESS (1) Rolls of paperboard are delivered to VisyPak Broadmeadows. (2) The rolls are
printed in up to 5 colours, (3) Paperboard is coated to a composite laminate that includes Aluminium
foil and low density polyethylene. (4) The coated paperboard is then cut into individual blanks and
creased to assist folding on the filling machine later. (5) The sleeve is folded, (6) and the seam sealed.
(7) The sleeves are inspected then packed and dispatched to the customer.

PurePak Manufacturing process

Blank cartons used in the Pure-Pak range of filling machines are manufactured at the VisyPak
manufacturing site located at Broadmeadows, Victoria.
They are produced using paperboard and an extrusion coating lamination of polyethylene plastic.

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THE PROCESS (1) Rolls of paperboard are delivered to VisyPak Broadmeadows. (2) Paperboard is
coated with low density polyethylene. (3) The rolls are printed in up to 4 colours, (3) cut into individual
blanks and creased to assist folding on the filling machine later. (4) The sleeve is folded, (5) and the
seam sealed. (6) The sleeves are inspected then packed and dispatched to the customer. (7) The
sleeves are fed onto the filling machine, (8) where the bases are constructed. (9) The cartons are
formed, filled and finally top sealed. (10) The finished cartons are conveyed downstream where they
are packed ready for distribution.

Comibloc and PurePak Manufacturing process – Step by Step

Step 1
Both - Rolls of paperboard are delivered to
Carton Plant

Step 2
2a. PurePak - The lamination of the paperboard
through an extrusion coating process. As a reel
of paperboard unwinds through the extrusion
line, the first extrusion station applies a layer of
polyethylene on the inner face of the
paperboard.

2b. A second extrusion station applies a shiny or

gloss
Polyethylene to the outer face of the
paperboard. This layer is ‘corona treated’ to
ensure good ‘ink adhesion’.
Combibloc - This step for Combibloc is
completed after the printing process.

Step 3
3a. Paperboard is printed via lithographic/ offset
printing press for CombiBloc. CombiBloc – The rolls
are printed up to 6 colours
3b. Flexographic technology is used for PurePak.
PurePak -The rolls are
printed up to 4 colours

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Step 4
Combibloc - During printing, a clear varnish
known as ‘adhesive’ is applied to a defined area
(pouring spout) of the top sealing flaps.

Step 5
Both - Then fed into a machine called a
“converter” where the reel of laminated paper is
printed, and then cut and creased, in individual
flat blanks that are automatically stacked ready
to be flame-sealed into finished carton blanks.
CombiBloc - As the web unwinds, it is
embossed with creases, slit lengthwise and cut
into blanks that are stacked onto pallets ready
for the next process.
Correct position and depth of creases are
essential to ensure cartons run efficiently
through the filling machine.

Step 6
Both - The flame sealer is loaded with the flat
blanks from the converter and these blanks are
continuously fed, individually, in to the machine.

CombiBloc - A gas flame melts the polyethylene

in order to seal the opposite edge to the blank,
with pressure applied with a pressure roller.
The sleeves are then folded back and forth
along the vertical creases, to assist opening in
the filler.

Step 7
The finished cartons are then counted, and
automatically boxed and palletised, before being
stored in the warehouse ready for despatch.

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Step 8
Carton Filling
The sleeves are fed into the filling machine where the bases are constructed. The cartons
are formed, filled and finally top sealed.
, neck dimensions and bottle weights are very accurate.

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