Sigma CapSeal

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Sigma CapSeal Induction Cap Sealing Machine

Wad Inserting Machine

Speed | 40 to 200 Caps/min

Depending on the closure/ cap design we can select from our array of cap feeders & cap transfer belts. The basic principal of our standard wad/liner inserting machines is to utilize a rotary indexer fitted with a star wheel to receive cap & closures in single or multiple lanes depending on the production needs of the project.
Each cap is fed into an individual pocket in the star wheel in order to maintain positive location while it moves through the machine. We have designed & developed several liner/Wad Inserting Machine stations with Single Head, Double Head & Four Head.
These heads use vacuum to pick and place precut liners/wads from a magazine into the cap.
All our machines can be used for inserting Induction as well as EP liners. Several optional value added features are available to enhance production quality.
Pre Cut Wad Inserting Machine Features

No.

Features

1
Machine can insert Induction wads & EP liners.
2
Wad Thickness 0.2mm to 1.2mm.
3
It can Handle Different cap Diameters & Shapes
4
High Productivity & Perfect Wadding
Induction sealing liner being inserted into a plastic cap before the sealing process.

We have meticulously designed and developed several liner/wad inserting stations featuring Single Head, Double Head, and Four Head configurations

Wide Range of Wad Inserting Machines

Speed 40-60 CPM
0 M+
Speed 80-120 CPM
0 M+
Speed 80-120 CPM
0 L+
Speed 160-200 CPM
0 M+
NO.
Specfication
Details
1
Speed (Output)
40-200 caps/min
2
Wad Types (Can Handle)
EP & Induction wads/liner
3
Wad Thickness
0.2mm-1.0mm
4
Cap Size
20mm-100mm
5
Electric Supply
415 VAC, 3 Phase, 50Hz

Watch Our Wad/Liner Inserting Machines in Operation

Value Added Features

No Wad, Reverse Wad, Batch Counter and Product Counter.
Cap Feeding Arrangements
Rotary Feeder
Cap Elevator
Vibratory bowl feeder
Hot Melt Applicator
Cold Glue
Vision Inspection Systems

Sensor Arrangement

Red cross icon representing rejection, defect detection, failed inspection, or non-compliant product identification.
NO Wad
Circular arrows icon representing continuous operation, process optimization, and automated production workflows.
Reverse Wad
Numeric sequence icon displaying 1, 2, 3, and 4, representing multi-up production configurations and throughput options.
Batch Counter
Numeric sequence icon displaying 1, 2, 3, and 4, representing multi-up production configurations and throughput options.
Product Counter

Vision Inspection System

This diagram illustrates different cap orientation arrangements—1-Up, 2-Up, 3-Up, and 4-Up—commonly used in automated cap feeding, sorting, and assembly systems. The configurations determine how many caps are processed simultaneously within a track or feeder, directly impacting machine speed and production capacity. Multi-up systems help improve throughput, optimize equipment utilization, and enhance operational efficiency in high-volume packaging and closure manufacturing applications.

Roll Feed Wad Inserting Machine

The caps are filled into the hopper in large quantity and will be fed to the elevator and then the elevator feeds the caps to the unscrambler. This unscrambler rotates at a high speed and feeds the cap to the in feed conveyor. Before entering into in feed conveyor the reverse caps are rejected and the caps with cavity facing upwards will be fed through in feed conveyor to the cap indexing mechanism. While the caps are indexed the wads (liners) are punched and then plunged into the caps through punch and plunger mechanism.
The wads are roll fed and for each index wads are punched and plunged into caps depends on the production rate you can choose for 1up, 2up and 3up punching configuration. Since the production rate is very high the caps before entering to infeed conveyor gets accumulated in a turn table accumulator so that the caps are fed to a conveyor at constant rate.
Once the caps are inserted with wads they come out through exit conveyor and gets collected in collecting bin. The production rate for machine 150 – 500 Caps Per Minute.
NO.
Specfication
Details
1
Speed (Output)
150-500 caps/min
2
Wad Types (Can Handle)
EP & Induction wads/liner
3
Wad Thickness
0.2mm-1.2mm
4
Cap Size
20mm-100mm
5
Electric Supply
410 VAC, 3 Phase, 50Hz

See How Roll feed Wad Inserting Machine in Operation

HSR 100
  • No.
  • Features
1
Speed: 100 – 150 Caps/Min
2
Machine Inserts Induction Wads & EP Liners
3
Remote Access
4
IoT
5
Vision Inspection
6
Maximized Liner Material Surface Utilization
7
Quick & Easy Change Over
HSR 100 automatic wad inserting machine with cap feeding and liner insertion system for plastic cap assembly operations.
HSR 160
  • No.
  • Features
1
Speed: 140 – 150 Caps/Min
2
Machine Inserts Induction Wads & EP Liners
3
Remote Access
4
IoT
5
Vision Inspection
6
Maximized Liner Material Surface Utilization
7
Quick & Easy Change Over
HSR 160 automatic wad inserting machine with cap feeding, liner handling, and insertion systems for plastic cap lining operations.
HSR 200
  • No.
  • Features
1
Speed: 250 – 300 Caps/Min
2
Machine Inserts Induction Wads & EP Liners
3
Remote Access
4
IoT
5
Vision Inspection
6
Maximized Liner Material Surface Utilization
7
Quick & Easy Change Over
HSR 200 automatic wad inserting machine with cap feeding and liner insertion system for cap lining applications.
HSR 300
  • No.
  • Features
1
Speed: 450 – 500 Caps/Min
2
Machine Inserts Induction Wads & EP Liners
3
Remote Access
4
IoT
5
Vision Inspection
6
Maximized Liner Material Surface Utilization
7
Quick & Easy Change Over
HSR 400
  • No.
  • Features
1
Speed: 600 -700 Caps/Min
2
Machine Inserts Induction Wads & EP Liners
3
Remote Access
4
IoT
5
Vision Inspection
6
Maximized Liner Material Surface Utilization
7
Quick & Easy Change Over
HSR 400 automatic wad inserting machine with cap feeding, wad placement, and inspection systems for high-speed cap lining applications.

Models- 1 UP, 2 UP, 3 UP and 4UP

Illustration showing 1-Up, 2-Up, 3-Up, and 4-Up cap orientation configurations used in automated cap feeding and assembly systems.

Closure Type

Cap turntable and accumulator system used for collecting, buffering, and feeding caps in automated packaging lines.
Cap Turn Table & Accumulator
Cap Elevator
Modular belt conveyor system used for automated product transportation in packaging and manufacturing lines.
In-Feed Conveyor
Industrial conveyor system used for automated product handling and transportation in packaging and manufacturing lines.
Exit Conveyor with Inspection Camera
Industrial machine vision camera used for automated inspection and quality control in packaging and manufacturing lines.
Vision Inspection System
Industrial hot melt adhesive applicator used for automated glue application in packaging and product assembly processes.
Hot Melt Applicator
Industrial dust extraction system with blower, flexible hose, and collection bag for removing dust and airborne particles from production environments.
Dust Extractor
Cardboard cartons moving on a conveyor system during automated packaging and material handling operations.
Box Conveyor

Benefits

Upward growth chart icon representing increased productivity, business growth, and improved manufacturing performance.

Increased Efficiency

Automation of the liner insertion process speeds up production, leading to higher output rates and reduced cycle times compared to manual insertion methods.

Hand holding an alert symbol icon representing proactive support, issue resolution, and customer assistance services.

Cost Savings

By minimizing labor requirements and increasing productivity, roll-fed machines can lower overall production costs over time, providing a return on investment.

Target and arrow icon representing precision, goal achievement, process accuracy, and performance optimization.

Improved Accuracy

These machines are designed for precise liner placement, reducing errors and waste associated with manual handling.

Interlocking gears icon representing system integration, process automation, and seamless manufacturing operations.

Versatility

Roll-fed liner inserting machines can handle various types of liners and container sizes, offering flexibility to adapt to different packaging requirements.

Clock and downward arrow icon representing reduced processing time, faster production cycles, and improved operational efficiency.

Reduced Downtime

With reliable performance and minimal maintenance requirements, roll-fed machines help minimize production downtime, maximizing operational uptime.

Gear icon representing process optimization, efficient equipment utilization, and space-saving manufacturing solutions.

Space Optimization

Compact designs and the ability to integrate into existing packaging lines allow for efficient use of floor space in manufacturing facilities.

Checklist and document icon representing quality assurance, compliance verification, and packaging inspection processes.

Compliance

Many roll-fed machines adhere to industry standards and regulations for packaging processes, ensuring compliance with quality and safety requirements.

Our Customers

Connect with Us for Tailored Assistance

Our team is dedicated to providing personalized solutions that meet your specific needs. Whether you require expert advice, detailed information, or custom sealing solutions, we’re here to assist you every step of the way.
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What Clients Say About Us

Trusted by clients in 85+ countries, our solutions speak for themselves. Read what our customers have to say about our quality, service, and reliability.

Induction Cap Sealing for Confectionery Packaging – Cadbury

We’ve been using Sigma CapSeal’s induction sealing machines for over five years now, and the experience has been exceptional. Their equipment is robust, easy to integrate, and has significantly improved our packaging efficiency. What stands out the most is their after-sales support — always prompt and professional. Truly a partner we can rely on.

Ricky Smith, Plant Manager, Global PharmaTech
Induction Cap Sealing for Confectionery Packaging – Cadbury

We’ve been using Sigma CapSeal’s induction sealing machines for over five years now, and the experience has been exceptional. Their equipment is robust, easy to integrate, and has significantly improved our packaging efficiency. What stands out the most is their after-sales support — always prompt and professional. Truly a partner we can rely on.

Vijay Avalaskar
Induction Cap Sealing for Confectionery Packaging – Cadbury
We’ve been using Sigma CapSeal’s induction sealing machines for over five years now, and the experience has been exceptional. Their equipment is robust, easy to integrate, and has significantly improved our packaging efficiency. What stands out the most is their after-sales support — always prompt and professional. Truly a partner we can rely on.
Ricky Smith, Plant Manager, Global PharmaTech

Feel Free to Get in touch!