Established by New Zealand’s leading business innovators, Recorp NZ aims to revolutionize the nation’s beverage market. More than just a producer of aluminum containers, the company supports brands of all scales, focusing on fostering new product development. Recorp’s model emphasizes client success with low minimum order quantities, a versatile selection of can sizes, and a passionate team committed to customer support.
In 2021, Recorp NZ initiated discussions with Belvac, drawn by its reputation for quality and expertise. What solidified the collaboration, however, was Belvac’s innovative approach to machinery design, emphasizing flexibility and efficiency.
With the rising demand for cans in New Zealand, Recorp NZ identified an opportunity to cater to brands of all sizes. Their vision was to become a comprehensive supplier offering a wide range of can sizes with low minimum order quantities. To support this flexible business model, they required a production line capable of meeting these demands. Entering a competitive market with narrow margins, Recorp NZ knew their approach would be challenging and prioritized finding a supplier that understood and could meet their unique requirements.
The front end during construction of the line.
New Zealand’s modest population creates an environment where mid to small-sized brands can compete effectively alongside global leaders, offering a diverse array of beverage choices to consumers. Bruce Parton, Recorp NZ’s chief executive officer, highlighted the company’s commitment to innovation: “Recorp was willing to invest additional capital in technology that led to faster changeover times in the factory helping us lower the MOQ for our customers. This in turn increases flexibility through new products which helps grow the overall market. Our operations supply all the current can sizes available in the New Zealand market. Coupling this capability with a highly automated and efficient plant, we offset common roadblocks other operations face like rising labor rates.”
Designing Solutions for Operational Goals
The project incorporates a single can making line capable of producing multiple can sizes. With an annual output of approximately 750 million cans, the line operates at speeds of up to 1,800 cans per minute (cpm), with the capacity to expand to 2,400 cpm.
Projects of this scale rely heavily on clear communication to ensure success. David Mammolenti, Belvac president, emphasized this importance, stating, “These projects are massive undertakings; however, we firmly believe that Belvac was best suited to support Recorp. We have assembled a talented team capable of delivering comprehensive solutions, from container design through life cycle support. Belvac was thrilled when Recorp chose to partner with us. This process demands thorough planning, along with a deep understanding of customers goals and mutual feedback, which set the project up for success. The collaboration of two dedicated teams working towards a common goal truly contributed to this project’s achievements.”
One of eight Belvac BM24 Bodymaker and CC93 Trimmer units.
Trimmer discharge onto conveyance.
Belvac designed a customized solution for Recorp NZ, achieving operational speeds of up to 1,800 cans per minute while maintaining the flexibility needed to meet customer demands. The line begins with the Belvac Cupping System, which supplies cans to eight Belvac BM24 Bodymakers and CC93 Trimmers. The BM24 Bodymaker, with its hypocycloid main drive, eliminates the need for foundations and vertical movements, resulting in reduced ram deviation, lower tear-off rates, and precise body wall thickness. Belvac’s CC93 Trimmers deliver burr-free, sliver-free, and step-free trimmed cans of exceptional quality. Additionally, the ARC Can Washer and Dry-off Oven are optimized for energy efficiency, reduced wastewater, and improved process performance.
One standout feature of this project is the Decorator area configuration. “The inclusion of a Basecoater and Pin Oven enables operators to apply a baselayer of ink, typically white, to the cans before label application, resulting in a more vibrant print due to enhanced pigmentation. After assessing Recorp’s needs, the Belvac team determined that the Decorator presented a probable area for bottlenecks. Anticipating frequent label changes, we opted to integrate a dual Decorator and Pin Oven system which will help reduce operational downtime while continually allowing Recorp to scale their contract sizes,” stated Tony Reynolds, Director, Integrated Solutions EMEAI.
The dual Decorator and Pin Oven System designed to support Recorp’s unique business model.
The back end of the line includes eight Inside Spray machines feeding into an ARC Internal Bake Oven, engineered for efficient heat retention and reduced utility usage. The setup also features two 595K VE Belvac Neckers, with one equipped with an intermediate infeed to facilitate the production of multiple can sizes. Standardized Necker turrets simplify size changeovers, minimizing downtime and enabling operators to make adjustments using common hand tools.
Belvac’s Intelligent Manufacturing System (IMS) and High-Speed Selective Sorter (HS3) further enhance operational efficiency. These tools provide real-time dynamic monitoring of plant processes, allowing operators to pinpoint spoilage causes by tracking, grouping, and prioritizing defects identified by vision systems in necking and upstream operations. The system enables operators to analyze defects using Pareto charts, sample cans, and sort without disrupting production speeds. Together, these features streamline downtime, reduce spoilage, and elevate quality control standards.
The ARC Internal Bake Oven on the back end of the line.
One of Two 595K VE Belvac Necker’s featuring an Intermediate Infeed.
Flexibility Makes Successful Projects
Bruce Parton, Recorp NZ’s chief executive officer, stated, “Belvac delivered a comprehensive system tailored to our specific needs. Throughout the project there were situations where we had to approach Belvac with changes, one instance in particular our operations encountered a major delay. The Belvac team reacted well with proactive problem solving and a partnership mentality. To get a plant up and operating in eight months has been extremely challenging for all of us, however quickly making high quality cans has resulted in us entering the market and winning customers.”
In addition to its expertise in project management, equipment engineering, and installation, Belvac provided essential support in areas often overlooked, such as container design and engineering services. David Mammolenti emphasized, “Belvac has invested in a team dedicated to designing high performing and lightweight containers, continually seeking opportunities to downgauge and support our customers both now and in the future.” Belvac’s capabilities also extend to bottle cans, with production-proven solutions successfully implemented in projects worldwide since 2007.
New Zealand’s prime minister, Christopher Luxton (left), attends the plant opening in November 2024. Next to him, Recorp’s CEO, Bruce Patron.
Belvac offers turnkey production lines with speeds of up to 3,600cpm, along with solutions tailored for lower volume operations. The company also excels in multi-size production lines, such as the one implemented for Recorp NZ. Additionally, Belvac specializes in bottle can production lines, typically rated between 600cpm and 1,200cpm, capable of manufacturing various bottle configurations and shapes with multiple closure options. Existing can making lines can also be equipped with bottle can cells, enabling dynamic and flexible production output.
For more information on these offerings
Visit Belvac’s Integration page or contact us at sales@belvac.com. To learn more about Recorp NZ, visit their website or reach out at info@recorp.com.
