HSR 100 Automatic Cap Lining Machine
Versatile one-up automatic cap lining for a wide range of closures: 20 mm to 120 mm, almost all liner materials.
The HSR 100 from Sigma CapSeal is a highly versatile, fully automatic cap lining solution built for the evolving requirements of modern cap and closure manufacturers. Built for flexibility, precision, and reliability, it processes an extensive range of cap sizes and liner materials, making it one of the most adaptable lining machines available in the market.
20 - 120 mm
Cap Range
180
Max CPM
One-Up
Configuration
IoT
Enabled
20 - 120 mm
Cap Diameter Range
150–180
Caps Per Minute
One-Up
Automatic Configuration
8 Types
Liner Compatibility
Vision
Inspection Ready
Hot Melt
Compatible
A Single Machine That Handles Your Full Cap Range
One of the biggest challenges faced by cap manufacturers is the need for a single machine capable of handling multiple cap diameters. The HSR 100 addresses this requirement with ease, accommodating cap diameters from 20 mm to 120 mm, with provisions for larger diameters through customized tooling.
Designed for flexibility, precision, and reliability, the HSR 100 processes an extensive range of cap sizes and liner materials in a compact, AI-integrated and IoT-enabled one-up configuration, making it one of the most adaptable lining machines available in the market.
Fully Automatic Operation, End to End
The HSR 100 runs the complete lining cycle automatically, from cap loading through to collection and boxing, with no manual handling between stages.
1
Automatic Cap Loading
Caps are loaded into the machine automatically, removing manual feeding at the infeed.
2
Cap Feeding & Orientation
Caps are fed and correctly oriented so each one is presented consistently for lining.
3
Conveyor Transfer
Oriented caps are carried through the machine on the conveyor to the lining station.
4
Liner Punching
Liners are punched to the required shape, from round to multi-tab and custom profiles.
5
Liner Insertion
Each punched liner is inserted and seated into the waiting cap.
6
Quality Inspection
Vision inspection verifies liner presence, position, orientation, and cap quality.
7
Counting
Lined caps are counted automatically for accurate batch records.
8
Collection & Boxing
Finished caps are collected and boxed at the exit, completing the cycle.
Why Choose the HSR 100
The capabilities that make the HSR 100 a versatile, future-ready lining machine for demanding packaging lines.
Wide Diameter Range: 20–120 mm
A single machine handles closures from 20 mm to 120 mm, with custom tooling available for larger diameters. One platform covers what would otherwise need several machines.
Suitable for Almost All Liner Materials
Runs induction seal liners (one-piece and two-piece), pressure sensitive, EPE foam, pulp board, heat seal, custom laminated, and special packaging liners.
Specialty & Dispensing Closures
Handles flip-top, dispensing, spout, trigger, child-resistant, specialty pharmaceutical, and custom molded caps and closures.
Advanced Liner Punching
Punches round, single-tab, dual-tab, tri-tab, five-tab, and custom-shaped liners to match your closure and sealing requirement.
Vision Inspection Ready
Supports inspection for presence of liner, correct liner position, cap defects, orientation verification, and quality compliance.
Compact, AI-Integrated & IoT-Enabled
A compact one-up design with AI integration and IoT connectivity, plus optional hot melt application integration for bonded liners.
Liner, Closure & Punch Compatibility
The HSR 100 is built around versatility. It is compatible with multiple liner types, handles specialty caps and closures, and punches a full range of liner shapes.
Compatible Liner Types
- Two-piece induction seal liners
- One-piece induction seal liners
- Pressure sensitive liners
- EPE foam liners
- Pulp board liners
- Heat seal liners
- Custom laminated liners
- Special packaging liners
Caps & Closures Handled
- Flip-top caps
- Dispensing caps
- Spout caps
- Trigger caps
- Specialty pharmaceutical closures
- Child-resistant closures
- Custom molded caps
Liner Punch Shapes
- Round liners
- Single-tab liners
- Dual-tab liners
- Tri-tab liners
- Five-tab liners
- Custom-shaped liners
HSR 100 in Production
Replace the placeholders below with actual machine, production line, and detail photos before publishing.
Full Machine View
Liner Punch & Insertion
Cap Feeding & Orientation
Vision Inspection
HMI / Control Panel
Counting Collection & Boxing
See the HSR 100 Run Your Caps and Liners
Bring your cap geometry and liner material, and our applications team will show the HSR 100 lining your closures. Discuss custom tooling for your diameters, vision inspection setup, and hot-melt integration where bonded liners are needed.
- Machine matched to your cap diameter and closure type
- Liner compatibility check for your material
- Custom tooling and vision inspection guidance
- Applications engineering Q&A
Talk to Sigma CapSeal
Engineering-led support with decades of field experience and responsive after-sales service.
Where the HSR 100 Is Used
Sigma CapSeal serves cap and closure lines across diverse manufacturing industries. The HSR 100’s liner and closure versatility suits each of them.
Healthcare & Pharma
Specialty pharmaceutical and child-resistant closures with induction seal liners.
Personal Care
Dispensing, flip-top, and pump-style closures across personal care formats.
Dairy
EPE foam and induction liners for dairy bottles and containers.
Food & Beverages
A wide cap range and liner choice for food and beverage closures.
Agro Chemicals
Trigger, spout, and larger closures with induction and laminated liners.
Petro Chemicals
Larger-diameter closures supported through custom tooling.
Confectionery
Lining for jar and container closures across confectionery packaging.
Speciality Chemicals
Custom molded and specialty closures with the appropriate liner type.
Automation, Inspection & Hot-Melt in One Platform
The HSR 100 runs the complete lining cycle automatically, from cap loading through to collection and boxing (see How It Works for the full sequence).
For applications requiring bonded liners, the machine can be integrated with a Hot Melt Adhesive Application System. Vision inspection integration verifies liner presence, position, orientation, and cap quality. Custom tooling is available to match your specific cap diameters and closure types.
HSR 100 Technical Specifications
Parameter summary for engineering evaluation and line specification.
- Parameter
- HSR 100 Specification
Cap Diameter Range
20 mm – 120 mm (larger diameters via customized tooling)
Production Speed
150–180 caps per minute
Configuration
One-up automatic cap lining
Liner Types
8 liner types
Liner Punch Shapes
6 shapes
Caps & Closures
7 closure types
Vision Inspection
Inspection-ready: liner presence, correct position, cap defects, orientation verification, quality compliance
Hot Melt Application
Optional integration with Hot Melt Adhesive Application System for bonded liners
Automatic Operations
Full automatic cycle
Tooling
Custom tooling available
Additional parameters such as footprint, power supply, and full certification details: contact Sigma CapSeal applications engineering. Configuration varies with cap and closure type.
51+
Years of Experience
5+
Decades of Engineering
Global
Reach & Service
MNC
Client References
Responsive Service
Sigma CapSeal pairs precision engineering with responsive after-sales service, so your line is supported well beyond installation.
Engineered and Dependable
Sigma CapSeal (Electronics Devices Worldwide Pvt. Ltd.) designs, manufactures and supports reliable induction sealing and cap/closure automation systems that improve product safety, line efficiency, and packaging integrity for manufacturers across FMCG, pharmaceutical, personal care, chemicals, and food industries.
With more than five decades of domain expertise, hands-on R&D, and close partnerships with multinational customers, the HSR 100 reflects Sigma CapSeal’s commitment to continuous innovation, practical engineering, and keeping customers’ products safe and production lines efficient.
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Frequently Asked Questions: HSR 100
Common questions from cap manufacturers and packaging teams evaluating the HSR 100.
What cap diameters does the HSR 100 handle?
It accommodates cap diameters from 20 mm to 220 mm, with provisions for larger diameters through customized tooling, so a single machine can line many different closures.
Which liner materials are compatible?
Two-piece and one-piece induction seal liners, pressure sensitive, EPE foam, pulp board, heat seal, custom laminated, and special packaging liners. The HSR 100 is suitable for almost all liner materials.
What liner shapes can it punch?
Round, single-tab, dual-tab, tri-tab, five-tab, and custom-shaped liners.
Can it apply hot melt adhesive?
Yes. The machine can be integrated with a Hot Melt Adhesive Application System for applications requiring bonded liners.
What is the production speed of the HSR 100?
The HSR 100 delivers reliable production speeds of 150 to 180 caps per minute.
What caps and closures can it line?
Flip-top, dispensing, spout, trigger, specialty pharmaceutical, child-resistant, and custom molded caps and closures.
Does it include vision inspection?
Yes, the HSR 100 is vision inspection ready, supporting checks for presence of liner, correct liner position, cap defects, orientation verification, and quality compliance.
Is operation fully automatic?
Yes. It performs automatic cap loading, cap feeding and orientation, conveyor transfer, liner punching, liner insertion, quality inspection, counting, and collection and boxing.
Ready to Specify the HSR 100 for Your Line?
Talk to a Sigma CapSeal applications engineer. Bring your cap geometry, liner specification, and closure type, and we’ll confirm fit and tooling for your line.