Plastic microparticles are no longer a minor technical detail; they directly impact product safety, regulatory compliance, and brand perception throughout the entire bottling cycle.
Every line that handles caps and closures inevitably generates dust and plastic fragments, with a potential effect on perceived quality and consumer safety.
A Real Risk for Product and Brand
During production, transport, and handling of caps, friction between plastic surfaces generates secondary particles that settle on conveyors, elevators, and orientation systems. These are compounded by airborne particles in the plant, which further contaminate the cap path.
The result is a tangible risk of microplastics ending up inside the container in contact with the product, potentially leading to recalls, non-quality costs, and reputational impacts that are difficult to recover, especially in food & beverage and highly hygienic sectors.
Evolving Regulations and Brand Requirements
The European Union introduced Regulation (EU) 2023/2055, limiting intentionally added microplastics in products as part of the broader roadmap toward zero plastic pollution. While secondary microparticles generated by industrial processes are not yet specifically regulated, the trend is clear: manufacturers will be required to implement increasingly stringent control of plastics along the supply chain.
Leading brands are anticipating this scenario, incorporating microplastic management into supplier qualification criteria, line specifications, and plant audits—transforming it from a mere technical requirement into a differentiating factor of reliability.
Why Act in the Capping Area
The capping area represents the final gate before the product leaves the line, with no further opportunities to intervene in particulate contamination. If dust and microparticles are present on caps at this point, the risk of transfer into the container is high.
For this reason, the most advanced players are investing in:
- Controlled environments along the cap path, with closed channels, filtered air (e.g., HEPA systems), and dedicated suction points.
- Dedusting systems installed directly at the capping machine, capable of selectively removing residues from the cap surface before closure.
Intervening here means acting at the point of maximum impact on product quality and compliance with end-customer standards, particularly in terms of safety.
Advanced Dedusting as a Competitive Lever
Next-generation dedusting systems do not simply move dust; they integrate ionization, filtered compressed air, and high-efficiency suction in a controlled process. This combination allows particles to be “lifted” from the cap surface and efficiently conveyed to dedicated collection units, reducing in-line dispersion and allowing for qualified management.
Independent laboratory tests, conducted with various cap types and particles (HDPE, cardboard, wood), show that such solutions can achieve removal efficiencies above 99.9% for certain size classes, maintaining stable performance even at typical high-speed line rates. This results in fewer particles in the product, greater safety for the end consumer, reduced exposure to claims, and greater confidence during audits and inspections.
Example Solution for High-Speed Lines
For example, AROL’s dedusting systems for caps are designed to integrate with most AROL and non-AROL down channels, with extensive retrofit options for existing lines. The Ion-B and Ion-Xcl models operate across a wide speed range, reaching configurations of 85,000 caps/hour while maintaining high particle removal efficiency.
These performances help manufacturers objectively document particulate contamination control, supporting quality dossiers, technical specifications, and responses to increasingly detailed ESG questionnaires.
An Investment in Protection and Positioning
Adopting a dedusting system is not just an engineering choice but a strategic brand protection decision.
By measurably reducing microparticle presence:
- Actual and perceived product safety is enhanced, reinforcing trust among consumers and industrial customers.
- Companies position themselves ahead of regulatory evolution, with data and indicators supporting compliance.
In a market where supplier differentiation is based on quality, reliability, and credibility, a bottling line that demonstrates advanced microplastic control becomes a tangible differentiator as well as a best practice in production.
