440M Wad/Liner Inserting Machine: High-Speed Induction/EP/Foam Liner Insertion
The SigmaCapSeal 440M is a fully automatic precut Liner/Wad inserting machine designed for accurately inserting EP, Foam and Induction Liners/Wads into plastic caps and closures.
Using a proven vacuum Pick & Place system, the machine inserts one precut liner into every cap at speeds of up to 160–180 caps per minute, ensuring consistent liner placement with high reliability and minimal operator intervention.
160-180
Caps Per Minute
20-50 mm
Cap Size
Induction/EP/Foam
Wad Type
PLC
Control System
160-180 CPM
Rated Speed
20-50 mm
Cap Size
Induction/EP/Foam
Wads
Material Handled
PLC
Control System
220/380/440V
Power Supply
Camera Vision
No-Wad / Reverse-Wad
Automatic EP, Foam & Induction Wad/Liner Insertion for 20-50 mm Caps
The 440M automatically inserts precut induction/EP/Foam wads into 20-50 mm caps. Caps are fed into a bowl feeder and oriented cavity-facing up, then carried by conveyor to a star wheel that holds each cap in position while a vacuum cup places a wad from the magazine into it.
The sensor arrangement catches a missing or flipped wad in the same motion that places a good one: no-wad and reverse-wad rejection runs through a camera vision system, with a rejected cap counter and an accepted cap counter tracking output. The whole line is PLC controlled from a 7-inch touch screen operator panel.
How the 440 M Works
Four stations, one continuous motion. Caps get oriented, wads are stacked and ready, the star wheel brings the two together, and the vacuum cup does the placing.
1
Cap Feeding and Orientation
Caps load into the bowl feeder and come out cavity-facing up, delivered by conveying belt toward the wadding station. A cap orientation validator sensor blows wrongly oriented caps back to the hopper.
2
Wad Magazine Stacking
Precut induction/EP/Foam wads sit stacked in the magazine, aluminum-facing down, staged and ready for the vacuum cup to draw from one at a time.
3
Star Wheel Indexing
A star wheel holds each cap in position as it indexes toward the wadding station, keeping placement repeatable at 160 to 180 CPM.
4
Vacuum Pick-and-Place
Each time the star wheel indexes, the vacuum cup lifts one wad off the magazine stack and sets it into the cap. No-wad and reverse-wad rejection with a camera vision system checks the result before the cap moves on.
Watch the 440M in Action
440M Spec Sheet
The full brochure PDF with dimensions, head options and accessory list, ready to forward to your engineering or procurement team.
Key Features and Engineering Advantages
Precut Induction/EP/Foam Wad Insertion
A star wheel and vacuum cup place a precut induction/EP/Foam wad from the magazine into every 20-50 mm cap.
Stainless Steel Bowl Feeder
Main bowl structure in stainless steel AISI 304 on an M S painted stand, with a quick-change cap sorter and an acrylic cover for dust-free operation.
Cap Orientation Validation
A cap orientation validator sensor checks each cap is cavity-facing up after the bowl feeder; wrongly oriented caps are automatically blown back to the hopper.
PLC Control with Touch Screen HMI
Programmable PLC (Mitsubishi / Panasonic) with a 7-inch color touch screen operator panel and a three-color alarm light.
160 to 180 CPM, Rated
Caps are fed, oriented, wadded and counted continuously at up to 180 caps per minute.
Automatic Box-Fill with Alarm Light
The exit conveyor’s two-position switch gate and cap counter fill boxes to your set quantity, with an alarm light prompting the operator to swap to the second box once the first is full.
Sensing Built Into Every Cycle
A cap orientation validator, a reverse cap sensor, and camera-vision no-wad/reverse-wad rejection watch the cap and wad through the cycle, with rejected and accepted caps each counted.
No Wad / Reverse Wad Rejection
A camera vision system checks for a missing wad or a wad seated the wrong way up.
Reverse Cap Sensor
Positioned on the entry conveyor near the star wheel; stops the machine if a cap arrives the wrong way round.
Rejected Cap Counter
A rejected cap sensor with counter tracks every cap that fails the wadding or orientation check.
Accepted Cap Counter
Running count of every cap that passes through the station successfully.
Cap Level Sensors
Level sensors on the cap elevator and at the entry and exit of the infeed conveyor start and stop the elevator, bowl feeder and wadding process as caps run high or low.
Construction
Mechanical, pneumatic and electrical build, per ED engineering drawings.
Mechanical
- Parts exposed to wear are standard, from international suppliers
- Parts not in stainless steel have corrosion-resistant coating or customer-specified paint
- Every part manufactured to its own drawing, per ED engineering
Pneumatic
- Festo / SMC make, per ED engineering
Electrical & Control
- Electrical cabinet per CEE electrical security directives
- PLC: Mitsubishi / Panasonic, programmable type (24VDC PNP)
- Operator panel: Mitsubishi 7-inch color touch screen
- Marked cables and connectored modules; inverters standard; Bonfiglioli gear box
What's Included, What's Optional
The infeed system ships as standard, built for dust-free operation end to end. One item is available on request but not included in the standard provision.
Standard Infeed System
- Cap elevator to bowl orientor, dust-free enclosed path
- Dual-track infeed conveyor with inverted cap removal at machine entry
- Adjustable guides for cap diameter, height and width
- Exit conveyor with counter and diverter
Optional: Camera Inspection System
- Not included in the standard infeed provision
- Adds a camera-based check at the infeed/exit conveyor
Full Sensor and Safety Arrangement
Every stage of the cap and wad path is monitored, and the machine is guarded to stop on demand or on fault.
- Sensor / Device
- Location
- Function
Cap Level Sensor
Cap elevator
Alarms and controls elevator level
Cap Level Sensor
Entry of infeed conveyor
Starts / stops the cap elevator motor
Cap Level Sensor
Entry and exit of infeed conveyor
High level stops the bowl feeder; low level stops the wad inserting process
Reverse Cap Sensor
Entry conveyor, near the star wheel
Stops the machine on a reversed cap
Cap Sensing
Entry of the star wheel
Confirms cap presence before indexing
No Wad / Reverse Wad Rejection
Wadding station (camera vision system)
Rejects caps with a missing or reversed wad
Rejected Cap Sensor with Counter
Exit
Counts rejected caps
Accepted Cap Counter
Exit
Counts accepted caps
Touch Sensor
Clutch mechanism
Safety stop
Door Safety Sensors
Guarding doors
Safety stop
Start / Stop / Emergency Button
Control cabinet
Manual start, stop and emergency stop
The equipment stops automatically under any of the above conditions. Security perimeter closure with hinged doors is fitted around the machine.
Cap Specification, Wads and Industries
What the 440M is built to run, and where it’s used.
Cap Specification
- Cap size: 20-50 mm
- Cavity-facing-up orientation
- Wrongly oriented caps auto-rejected back to hopper
Wads
- Precut induction/EP/Foam wads
- Stacked aluminum-facing-down in magazine
Where It's Used
- Pharmaceutical and healthcare packaging
- Food and beverage bottling
- Personal care and cosmetics
- FMCG production lines
- Agrochemical, specialty chemical and lubricant fills
Industries Running the 440M
The 440M is built for manufacturers of plastic caps and closures needing automatic insertion of precut EP, Foam or Induction liners/wads — widely used across pharmaceutical, food, beverage, chemical, lubricant and agrochemical production, where consistent liner placement and high product quality are essential.
Pharma & Healthcare
EP, Foam and Induction liner insertion checked by vision inspection before the cap moves on.
Food & Beverages
EP, Foam and Induction liner insertion at up to 180 caps per minute.
Personal Care
Consistent liner placement for 20-50 mm caps.
Agro & Specialty Chemicals
Reliable liner insertion for chemical container closures.
FMCG
High-volume liner insertion built into fast-moving consumer goods packaging lines.
Pharma
Precise EP, Foam and Induction liner placement for pharmaceutical closures, inspected on every cycle.
Specialty Chemicals & Lube Oil
Dust-free liner seating for specialty chemical and lubricant container closures.
440 M Technical Specifications
- Parameter
- 440 M Specification
Machine Type
Fully automatic precut Liner/Wad inserting machine
Purpose
Automatically inserts precut EP, Foam and Induction liners/wads into the cap
Rated Speed
160 to 180 caps per minute (CPM)
Wad Type
Precut EP, Foam and Induction liners/wads
Cap Size
20-50 mm
Cap Feeding
Cap elevator to bowl orientor (stainless steel AISI 304 bowl, M S painted stand), dual-track infeed conveyor
Wad Feeding
Stacked magazine, aluminum-facing down
Indexing Mechanism
Star wheel
Placement Mechanism
Vacuum cup pick-and-place
Orientation Check
Cap orientation validator sensor; wrongly oriented caps blown back to hopper
Sensor Arrangement
Cap level sensors, reverse cap sensor, no-wad / reverse-wad rejection with camera vision, rejected cap counter, accepted cap counter
Exit
Two-position switch gate with cap counter, alarm light on box-full
Control
PLC (Mitsubishi / Panasonic), 24VDC PNP, 7-inch color touch screen operator panel
Power Supply
220/380/440V AC, 50/60Hz+N+T; auxiliary control voltage 24V DC
Working Environment
Temperature 5-40°C; relative humidity 20-85%
Pneumatics
Festo / SMC
Safety
Start/Stop/Emergency button, security perimeter with hinged doors, clutch touch sensor, door safety sensors
Optional Equipment
Camera inspection system
Cap samples should be inspected by our applications team to confirm the scope of supply for your line.
50+
Years of Experience
85+
Countries Served
250+
Engineers on the Team
35
Global Service Centers
One-Stop Solution: Insertion to Inspection
Sigma CapSeal designs and builds the full closure line — wad/liner insertion, cap assembly, induction sealing and vision inspection — so every station on your line is specified, quoted and serviced by the same applications team.
Why Choose the 440M
Sigma CapSeal has built wad/liner insertion, cap assembly, induction sealing and vision inspection equipment since 1974 and shipped India and Asia’s first induction sealer in 1989. That’s the same engineering group behind the 440M’s feed, index and placement mechanism, backed by a DSIR-certified R and D lab and equipment running in more than 85 countries.
Trusted by leading manufacturers worldwide
Nestle
Sun Pharma
Dr. Reddy’s
Tata Tea
ITC
Syngenta
Alpla
Frequently Asked Questions: 440 M
What packaging engineers, procurement teams and QA managers ask before they buy.
How does the 440M insert liners into caps?
Caps are loaded into the hopper and transferred by a cap elevator to a bowl orientor, which orients them before they discharge onto the conveyor. A precision star wheel indexing system positions four caps at a time beneath a vacuum Pick & Place head, which lifts a precut EP, Foam or Induction liner from the magazine and places it into each cap. A Liner Presence/Absence Detection System then inspects every cap and automatically rejects any without a liner.
How fast does the 440M run?
160 to 180 caps per minute.
How does it catch a missing or misoriented cap or wad?
A cap orientation validator sensor blows wrongly oriented caps back to the hopper. A reverse cap sensor stops the machine near the star wheel. A Liner Presence/Absence Detection System automatically rejects any cap without a liner, with a rejected cap counter and an accepted cap counter tracking output.
What cap size and liner type does it handle?
20-50 mm caps, with precut EP, Foam and Induction liners/wads.
Is the 440M PLC controlled?
Yes, on a programmable PLC (Mitsubishi or Panasonic) with a 7-inch color touch screen operator panel.
What's the power requirement?
220/380/440V AC, 50/60Hz+N+T, with an auxiliary control voltage of 24V DC. Rated for 5 to 40 degrees C and 20 to 85 percent relative humidity.
Spec a 440 M for Your Line
Send us a cap sample for inspection. Our applications team will confirm the scope of supply before you commit.
