High-level engineering solutions
At Zertec, we act as a technical arm of your plant, combining hands-on shop-floor experience with high-level engineering to solve chronic problems of wear, losses (spoilage) and line stoppages. We know that on 2-piece can lines running at very high speeds, every minute of machine downtime represents a significant loss. That is why our solutions are designed to ensure dimensional stability, repeatability and maximum durability under severe operating conditions.
Lean Manufacturing
Total focus on eliminating the 8 major operational wastes (overproduction, waiting, transportation, overprocessing, inventory, motion, defects and underutilized skills).
Six Sigma (DMAIC)
A data- and statistics-driven structured approach (Define, Measure, Analyze, Improve and Control) to minimize deviations and stabilize industrial processes.
Kaizen & Rapid Response
A culture of fast-response continuous improvement on the shop floor, focused on practical, low-cost changes with direct involvement of operations.
Sustainable PDCA Cycle
An iterative method (Plan, Do, Check, Act) to ensure the sustainability, stability and continuous refinement of every project implemented.
Reverse Engineering & 3D Modeling
Custom development of obsolete parts, materials testing and structural improvements for critical components and spare parts.
Polyurethane (PU) & Special Rubbers
Manufacturing and covering of inking rollers for 2-piece cans (Rutherford and Concord printers), PU rollers and molded technical parts.
Machine Rebuilds & Overhauls
Complete overhaul and maintenance of equipment for Can Makers (Bodymakers, Cuppers, Neckers, Trimmers, Decorators) to original factory tolerances.
CUSTOM SOLUTIONS
Reverse engineering and advanced 3D modeling
At Zertec, Reverse Engineering goes far beyond simply scanning an existing part. We use precision technology and advanced CAD modeling to reinterpret, optimize and localize components for 2-piece can manufacturing lines, ensuring performance equivalent or superior to that of original equipment manufacturers (OEM). We turn worn, broken or obsolete components into high-fidelity digital models (Digital Twin), enabling the manufacture of spare parts with full interchangeability and operational reliability.
- Reverse Engineering and Continuous Improvement: We analyze parts with a history of failures and redesign geometries, materials and heat treatments to exceed the service life of the original (OEM) components.
- Drastic Downtime Reduction: Subassemblies and mechanical modules developed under the Plug & Play concept, reducing setup and preventive maintenance time.
- Localization of Critical Parts: Development of highly complex spare components to international standards, ensuring agile lead times and independence from foreign markets.
ELASTOMERS DIVISION
Polyurethane (PU) rollers and special rubbers for inker’s
At Zertec, we develop and manufacture polyurethane (PU) inking rollers, special rubber compound rollers and high-alloy steel rollers, designed to meet the rigorous printing and coating requirements of 2-piece can lines. We turn complex demands into high-performance solutions that ensure dimensional stability, high chemical resistance to UV inks and solvents, and absolute geometric precision at high speeds.
Polyurethane (PU) and Special Rubber Roller Solutions
- Inker Rollers and Varnish Applicators: Formulated with high-resilience polyurethane and elastomeric compounds specifically developed to resist abrasion and chemical attack from UV-curing inks and industrial solvents.
- Hardness Stability (Shore A): Strict control of hardness and elasticity, ensuring the exact amount of ink and uniform coverage with no profile deformation during continuous operation.
- High-Precision Grinding and Lapping: Cylinders with near-zero runout tolerance, eliminating load variations and color registration defects (ghosting).
Special Steel Roller and Cylinder Solutions and Gravure Rollers
- High-Alloy Steels and Heat Treatment: Made from special steels (such as ground and nitrided tool steel), designed to withstand high compressive loads, frictional wear and mechanical fatigue.
- Coatings and Surface Finishes: Options include hard chrome plating, nitriding, or a high-precision mirror finish, reducing residue adhesion and facilitating cleaning setups . Anilox coating, engravings, and various weights are also available.
- Surface Coatings and Finishes: Options include hard chrome, nitriding, or a high-precision mirror finish, which reduce residue sticking and make cleaning easier. Anilox coatings with engraved geometries for application variation and weight reduction are also available.
- Dynamic Balance and Geometric Precision: CNC machining and grinding with dynamic balancing for high-speed operations, preventing vibrations that compromise print quality and equipment bearings.
MECHANICAL REFURBISHMENT
Complete Rebuilds & Overhauls for Can Maker machines
Zertec performs heavy engineering services for Rebuilds (complete reconstruction) and Overhauls (general and preventive overhaul) on Cuppers, Bodymakers, Trimmers, Decorators, Neckers, Light Testers and Palletizers. The process restores the original equipment manufacturer’s (OEM) nominal dimensional tolerances and operating clearances, with optimizations in heat treatments and tribology to extend the equipment’s service life. Severe wear on transmission components, cam tracks and sliding surfaces results in loss of geometric alignment, increased scrap rates (spoilage) and unplanned stoppages due to mechanical failure.
Need a custom solution?
Our engineering team is ready to analyze your production line and develop the ideal project for your productivity and yield goals.