Founded by some of New Zealand’s brightest business minds, Recorp NZ says it is positioned to disrupt the country’s beverage market. Representing “more than just a manufacturer of aluminum containers,” Recorp NZ caters to brands of all sizes, driven by a commitment to support new product development in the region. Its business model prioritizes customer growth, offering low minimum order quantities, a flexible range of can sizes, and an enthusiastic team dedicated to supporting clients.
Recorp NZ began discussions with Belvac about a project back in 2021. Belvac’s reputation for quality and expertise initially interested Recorp NZ, but it was the company’s innovative approach to machinery design, focusing on flexibility and efficiency, that ultimately led to this collaboration.
Recognizing a growing demand for cans in New Zealand, Recorp NZ saw a key market opportunity for a supplier that could support brands of all sizes. By positioning itself as a full-range supplier, its goal is to meet the needs of customers of all sizes, offering a diverse array of can sizes with low minimum order quantities. Building a business around flexibility, Recorp NZ needed a production line that could also support these requirements. Entering a highly competitive market with low tolerances, the company understood its approach would be challenging. Recorp NZ’s top priority was finding a supplier who recognized these distinct needs.
The front end during construction of the line.
New Zealand’s relatively small population allows for mid to small-sized brands to thrive alongside global leaders, facilitating a wide range of beverage options for consumers. “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,” explained Bruce Parton, Recorp NZ’s chief executive officer.
Designing Solutions for Operational Goals
The project features a single can making line with multiple size capabilities. The line is expected to produce around 750 million cans annually, with an operational speed of up to 1,800 cans per minute (cpm) that is expandable to 2,400cpm.
Effective communication is vital for projects of this magnitude. David Mammolenti, Belvac president, stated, “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.”
Left: One of eight Belvac BM24 Bodymaker and CC93 Trimmer units.
Right: Trimmer discharge onto conveyance.
Belvac tailored a solution to meet Recorp NZ’s specific needs, operating up to 1,800cpm while providing flexible operations to meet customer requirements. The front end commences with the Belvac Cupping System which feeds cans into eight Belvac BM24 Bodymakers and CC93 Trimmers. Utilizing hypocycloid main drive, the Bodymaker has no foundation requirements, in addition to no vertical movements which results in low ram deviation reducing tear-off rates and producing accurate body wall thickness. Belvac’s CC93 Trimmers produce high quality burr-free, sliver-free, step-free trimmed cans. The ARC Can Washer and Dry-off Oven have been engineered for energy efficiency, wastewater reduction and process optimization.
A unique aspect of this project is the configuration of the Decorator area. “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,” explained Tony Reynolds, Director, Integrated Solutions EMEAI.
The dual Decorator and Pin Oven System designed
to support Recorp’s unique business model.
The back end features eight Inside Spray machines that feed into an ARC Internal Bake Oven which is designed for optimal heat retention and minimized utility consumption. The line features two 595K VE Belvac Neckers, one of which is equipped with an intermediate infeed allowing for flexibility between producing multiple can sizes. The Necker turrets are standardized which reduces downtime requirements for can size changeovers and gives operators more flexibility to use common hand tools when making machine adjustments.
The addition of Belvac’s Intelligent Manufacturing System (IMS) and the High Speed Selective Sorter (HS3) provides operators real-time dynamic monitoring of the plant’s processes helping to locate the root cause of spoilage by tracking, grouping and prioritizing vision system defects of necking and upstream operations. This system allows operators to quickly review Pareto charts which group various defects, in addition to sampling and sorting without interrupting normal production speeds. Working in tandem, their features are optimized, reducing downtime and spoilage rates, while also improving quality control processes.
Left: The ARC Internal Bake Oven on the back end of the line.
Right: One of Two 595K VE Belvac Necker’s featuring an Intermediate Infeed.
Flexibility Makes Successful Projects
Bruce Parton, Recorp NZ’s chief executive officer, said, “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.”
Beyond project leadership, line design, equipment engineering and installation, Belvac also provided critical support in areas often overlooked. Container design and engineering services is one of those areas where Belvac has continually pushed innovation. David Mammolenti noted, “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.” These capabilities are also production-proven for bottle cans, which Belvac has successfully integrated into projects globally 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 provides turnkey lines rated up to 3,600cpm, with solutions available for lower volume production. In addition, Belvac specializes in lines with multiple size capabilities, like Recorp NZ. Another area of specialty for the company is bottle cans. Typically rated from 600cpm to 1,200cpm, these lines produce a variety of bottle configurations and shapes with multiple closure options. Existing can making lines may be fitted with bottle can cells for dynamic production output.