Flip Cap Assembly Manufacturing Innovation

When a client faced a looming production deadline for a newly designed bottle cap, Accel’s engineering team delivered a rapid automation solution in just three weeks. By leveraging 3D printing, custom control modules, and pneumatic presses, we created a one-of-a-kind production line that increased output 14 times over the client’s existing manual press process. The system included visual guides for assemblers to ensure quality placement, allowing the client to meet critical market timelines. The impact allowed a major retailer to place 7.3 million units on shelves on schedule, representing $146 million in revenue at $20 per unit. This case exemplifies Accel’s ability to deliver manufacturing solutions that reduce costs while increasing both quality and efficiency.