Karmelle Ltd

With 2020 just around the corner, we’ve been reflecting on another busy year here at Karmelle Ltd. The last 12 months have seen us appoint several new team members, develop our growing servicing and spares department and unveil some exciting new innovations – all while helping a range of companies to automate their liquid packaging processes. Take a look at our 2019 highlights…

January

Back in January we turned our attention to the year’s hottest topic – sustainability. This blog post explored the waste-reducing benefits of automation.

April

In April, Karmelle Ltd machinist Martin climbed Kilimanjaro in aid of Prostate Cancer UK. He’s now back on the shop floor, and planning his next adventure!

May

May saw us install a new Mini Monoblock gin filling, capping and labelling system at North Yorkshire distillery Raisthorpe Manor. Read more about the project here.

June

We celebrated World Gin Day with this blog post about our distillery partners – from Masons Gin to Ireland’s Blackwater.

October

In early October Karmelle returned to the PPMA Total show. It was a chance for us to showcase our filling, capping and labelling systems alongside some of the packaging industry’s biggest names.

November

Tomorrow’s Engineers Week gave us the perfect excuse to shout about our own fantastic team – like newly-appointed Workshop Manager Dave, who participated in this Q&A.

December

With the year drawing to a close, we’ve been tying up projects and delivering equipment. This versatile Rotary Capping Machine was bound for a manufacturer of sauces.

We’d like to thank our customers, partners and suppliers for their support in 2019. Here’s to another successful year!

Since its launch in 2017, our state-of-the-art Rotary Capping Machine has enabled numerous Karmelle customers to increase production and streamline their packaging processes.

Capping up to 60 containers per-minute, it offers high levels of accuracy and cost-cutting efficiency. Our latest system, built for a manufacturer of sauces, is a prime example.

The customer in question produces a number of product variants, and needed high-speed capping equipment that could handle several different container and closure types.

Their new machine was to be integrated into an existing line, with containers fed directly from a hot filling station.

Keeping these requirements firmly in mind, we manufactured a Rotary Capper with easy-to-fit change parts for the three containers and caps – including a large food tub and lid.

The result was a capping system offering, not just efficiency, but also excellent production flexibility – a key requirement in today’s competitive marketplace, which demands that manufacturers provide both variety and value-for-money.

Learn more about our range of capping machinery here…

4th – 8th November is Tomorrow’s Engineers Week, a five-day long campaign launched to celebrate the changing face of the industry and inspire a new generation of creators. Engineering is what we do here at Karmelle Ltd, and we couldn’t miss the opportunity to celebrate our own fantastic team. First up, a Q&A with newly appointment workshop manager Dave. A busy dad with a passion for vintage camper vans, he’s always enjoyed making things…

Dave, tell us how long you’ve worked in the engineering industry.

I have worked in engineering for around 17 years now. I cut my teeth as an engineer at a textile mill when I was 18. I went to college once a week for 3 years, where I earned an advanced diploma in maintenance engineering.

After working there for around 7 years I needed more of a challenge and left to work in the development department for a high-end bed company, where we developed new machinery that pocketed springs into fabric and even trainers for a leading sports brand.

Leaving there after 4 year brought me back into a maintenance role at a large paving company whose products are seen throughout UK towns and cities. It was there that I learnt engineering on a larger scale, as the machines were big and very industrial.

That brings me to Karmelle Ltd. I’ve been at Karmelle Ltd for just over 2 1/2 years, working with a team of engineers to build filling and capping machines and assist with on-site support and installations.

Why did you decide to pursue a career in engineering?

I was offered an apprenticeship in engineering when I was 18 and jumped at the chance. From a young age I was always taking things to pieces and building new projects, so being an engineer made total sense to me.

What’s your favourite aspect of the job?

My favourite aspect of the job is seeing a new idea or concept getting developed, and then seeing it come to life on the shop floor.

What does the future hold for the sector?

I think that the sector will progress in terms of faster, more intelligent equipment to run our machines. However, stripping all that back, you still need the nuts, bolts, bearings and other components to hold everything together, and I think these fundamentals will never change. I think development plays a big role in engineering, and the need to improve or make things more efficient drives the industry forward. Looking for ‘greener’ and ‘low cost’ solutions to run our technology is also key in manufacturing today, and we could see changes in the way we power our homes and factories in the future.

Earlier this year, we were saddened to learn that Masons Yorkshire Gin’s distillery had been badly damaged in an accidental fire.

While no one was hurt in the blaze, Masons lost everything – including this bespoke filling, capping and labelling line, manufactured and installed by Karmelle Ltd last year.

It was a devastating blow, but Karl, Cathy and the team quickly rallied, relocating to temporary premises, sourcing manual bottling equipment and re-distilling with the help of other producers.

They’ve handled every new challenge with characteristic grit and good humour, even launching a special edition gin, ‘Smouldering Heights’, in collaboration with The Boutiquey Gin Company.

Now, Masons are ready to re-automate their bottling process, and have asked Karmelle Ltd to manufacture and install a new filling, capping and labelling line.

Like their original system, it will comprise Rotary Infeed and Collection Tables, a Linear Air Rinser, a 4 Head Filler, a ‘T’ Cork Capping Machine and two automatic labelling systems.

Once installed in their new distillery, the line will automatically fill and cork a range of bottles, as well as applying body and ‘watch strap’ labels to a high degree of accuracy.

We’re thrilled to be supporting Masons as they embark on an exciting new chapter. What’s more, the project has given our technical team the opportunity to refine this bespoke system, which is currently in-build in our workshop. Stay tuned for updates, and take a sneak peek at Masons’ new premises here!

It’s that time of year again: PPMA, the UK’s leading processing and packaging machinery event, is just around the corner, and Karmelle are preparing to attend!

This year sees the return of PPMA Total, a bumper edition comprising PPMA, Pakex and Interphex. Between 1^st and 3^rd October, hundreds of visitors will flock to Birmingham’s NEC to see the latest innovations in processing and packaging technology. We’ll be there on stand E32, along with a range of modular filling, capping and labelling equipment. Here are three very good reasons to visit us…

Looking to fully automate your liquid packaging process? We’ve got turnkey systems, designed to do just that…

A Karmelle filling and labelling line

This year, we’ll be showcasing fully-automatic filling, capping and labelling machines, which can be integrated to form a complete line. This is your chance to see all the components of a turnkey liquid packaging system side-by-side! We’ll talk you through each stage of the process, and introduce each machine – from a 4 Head Inline Filler, to a high-speed Rotary Capper and state-of-the-art Front, Back and Three Point Wraparound Labeller. You’ll even see the Rotary Capper and labeller in action, as well as learning more about how a system like this could be adapted for your product.

4 Head Inline Filling Machine

A Karmelle Rotary Capping Machine

Need a semi-automatic filling solution? We’ve got those too…

If you’re not ready to fully automate your liquid packaging process, you can see several semi-automatic filling machines on the stand. We’ll be demonstrating an entry level Bench Top Filler; pneumatic and easy-to-operate, this affordable system is ideal for companies looking to make the switch from hand-filling.

We’ll also be showcasing a Semi-Automatic Flowmeter Filler, which can handle slightly larger batches and volumes. Thanks to its flowmeter control, it requires minimum clean-down – ideal for those packing a range of different products.

A Karmelle Bench Top Filler

Got a liquid packaging problem? Talk to the experts…

Whether you need to find the right filling solution for your problem product, or automate your entire packaging operation without involving multiple suppliers, it always pays to consult the experts. This year, our technical team – including Operations Director Brian and Labelling Engineer Grahame – will be on hand to answer your questions. Want to book an appointment? Just call 01484 533356 or email karmelle@gmail.com.

As if that wasn’t enough, we’ll be sharing exclusive case studies, showcasing images of our latest Atex filling and capping line, and handing out Karmelle goody bags. Don’t miss the most eagerly anticipated processing and packaging machinery event of the year! You can register for a ticket here.

At Karmelle, we’ve always served a range of market sectors – but, in recent years, our team have undertaken some particularly ambitious and successful automation projects for distilleries. Working with spirits presents a unique challenge, and many of our latest innovations – from the T Cork Capper, to the Mini Monoblock – came about as a direct result.

And what better reason than World Gin Day to shout about our fantastic distillery clients? We’re consistently wowed by their commitment and enthusiasm – not to mention the quality of their products! Meet the spirits brands we’re proud to call customers…

Masons Yorkshire Gin

Earlier this year, the spirits industry was rocked by news that multi-award winning Yorkshire distillery (and Karmelle customer) Masons had lost everything in a fire at their Bedale facility. What the blaze didn’t destroy, however, was this remarkable brand’s Yorkshire spirit. Two months on, and Masons are producing their delicious gins at a temporary premises, with a view to opening a new distillery in the near future.

Husband-and-wife Karl and Cathy Mason founded their eponymous brand in 2013. Today, the couple and their team use a traditional slow-distillation method to produce a range of hugely popular gins – from The Original, to special editions Tea, Lavender, Steve’s Apple, Peppered Pear and Sloe.

This approach to distilling – innovative, but informed by traditional methods – has won Masons widespread acclaim, and a clutch of awards – including, most recently, 3 golds at The Stuttgart International Spirits Competition.

Not that they’re about to rest on their laurels! The Masons events team are always looking for new ways to engage with customers, and recently opened a gin garden at the Birmingham Hippodrome, to celebrate the launch of its Calendar Girls production.

To mark World Gin Day and their sixth birthday, the brand have also organised a special ‘Gin Trail’. Taking place in bars across York, Leeds, Sheffield and Teeside, it will run until Sunday 9^th – so there’s still time to join the fun!

Follow Masons’ progress on ‘The Masons Phoenix – A Journal’, and look out for its new book, The Little Book of Gin, which was launched in partnership with The Ice Company.

Blackwater Distillery

One of our first spirits clients, world-renowned Irish distillery Blackwater takes its name from the nearby Blackwater river. The brand was launched by Peter Mulryan and Kieran Curtin, former TV industry professionals with a passion for craft distilling.

Using real botanicals, and inspired by the river’s history as a key channel for imported spices, Peter, Kieran and their team produce several small batch gins – including the multi-award-winning Blackwater No. 5.

We were lucky enough to partner with Blackwater in 2016, designing and manufacturing a bespoke filling and labelling system for its Cappoquin distillery.

Since then, the brand has continued to go from strength-to-strength, opening a new distillery in Ballyduff, and adding pot still Irish whisky to its product-range.

Scroll through the blog, and you’ll soon realise that Blackwater is more than just a business; it’s a labour of love, headed-up by genuine and hugely knowledgeable enthusiasts.

Blackwater Distillery’s Gin Garden

And, when they’re not distilling, Peter, Kieran and the team are looking for new ways to bring ‘good gin’ to the masses. Most recently, this has involved a Blackwater Gin Garden at Bloom 2019. Designed by The Hairy Gardeners, the ‘little green oasis’ featured lush foliage, reclaimed materials, and plenty of space to enjoy some craft-distilled gin!

Raisthorpe Manor

Earlier this year, our team designed, manufactured and installed a Mini Monoblock bottling system for North Yorkshire distillery Raisthorpe Manor. You can read more about the project here.

Launched in 2008, Raisthorpe are a family-affair; in fact, founders Julia and David Medforth began producing homemade liqueurs in the farmhouse kitchen of their country estate. Their raspberry gin (based on an old family recipe) proved such a hit with visitors to the Raisthorpe hunting lodge that soon, they were taking orders.

More flavours followed – from an award-winning oak aged Yorkshire dry gin, to sloe, damson, rhubarb and blueberry editions. RDPE funding enabled Raisthorpe to move its operation to a brand new factory facility – and the rest in history!

The North Yorkshire countryside remains at heart of this operation, with Julia, David, and their team making good use of locally grown fruit and water from nearby springs. The Medforths make a concerted effort to employ local people, and are familiar faces at shows and events throughout Yorkshire.

Happy World Gin Day to all our distillery clients! The Karmelle team will be raising a glass to you this evening.

British liquid packaging specialists Karmelle Ltd are set to unveil a new indexing capping machine at 2019’s PPMA Total Show, which will take place on October 1^st, 2^nd and 3^rd at the NEC, Birmingham.

The new capper has bridged a gap in Karmelle Ltd’s turnkey product range, which comprises modular, British-made filling, capping and labelling machines, designed to work independently or as part of a complete line. Christened the ‘Antelope’, it can achieve speeds of up to 40 bpm (depending on container-type), and will enable customers to increase production without investing in rotary capping equipment.

Indeed, the Antelope combines speed and efficiency with the versatility of an inline machine, and is capable of handling containers ranging from 100ml to 25L. Suitable for almost any closure, it also offers excellent repeatability.

Visitors can see the Antelope Capper on Karmelle’s stand, E32, where it will be running alongside a range of liquid filling and labelling equipment. Directors Peter Krawczuk and Brian Dickinson and Labelling Technician Grahame Rawlinson will be on hand to provide machinery demonstrations and expert advice.

Brian commented: “The Antelope Capper’s versatility makes it ideal for any number of products; while it is capable of capping small bottles at high speeds, it can be easily adjusted to handle much larger containers.

It was developed as part of an ATEX project for a leading manufacturer of automotive products. This client needed to fill and cap 2.5L and 5L containers, as well as 20L and 25L bottles – for which a rotary capper would have been unsuitable.

The Antelope has enabled our client to achieve its required production speeds for smaller volumes, while accommodating these larger containers.”

To learn more about this ATEX project, and see Karmelle’s British-made liquid filling machines, cappers and automatic labellers in action, visit them on Stand E32, call +(0)1484 533356, or go to www.karmelle.com.

Turnkey liquid packaging specialist Karmelle Ltd recently designed and manufactured a complete filling, capping and labelling line for Yorvale, enabling the ice cream brand to bring its new kefir drink, Yorlife, to market.

Yorvale has been producing real dairy ice cream on its farm, Fossfield, for almost 30 years – and approached Karmelle after adding kefir to its product range.

The brand needed hygienic, quick-strip equipment, capable of filling, capping and labelling 230ml and 500ml bottles.

Karmelle’s team designed and manufactured a complete line, comprising an air rinser, flow meter filler, three-head rotary screw capper, automatic labeller and collection table.

The equipment was installed in a custom-built production room on Fossfield Farm.

Since its installation, Karmelle’s engineers have added two new filling heads to help Yorvale meet demand for its kefir. The line is now running at 60 bottles per minute.

Yorvale’s Managing Director, Ian Buxton, said: “We chose Karmelle because of its reputation for both high-quality machinery and excellent after-care.”

For more information, visit www.karmelle.com, email Rosie Crampton at rose.crampton@karmelle.com, or call 01484 533356.

To learn more about Yorlife, visit www.yorlife-kefir.co.uk.

British filling, capping and labelling specialist Karmelle Ltd will showcase a range of machines at PPMA this September - building on its reputation for, not just high-quality, stand-alone equipment, but also complete liquid packaging systems.

The past five years have seen well-established machinery manufacturer Karmelle invest in both its workforce and facilities, enabling it to take on increasingly ambitious turnkey projects.

Most recently, its team designed, manufactured and installed complete filling, capping and labelling systems for Masons Gin, and kefir producer Yorvale.

Managing directors Peter Krawczuk and Brian Dickinson are keen to share these developments with PPMA’s attendees, and will be showcasing machines from their filling, capping and labelling ranges.

Visitors to the Karmelle stand, D46, will have the chance to see an in-line volumetric filling machine, a ‘T’ cork capping machine, and an automatic labelling machine – all of which can be integrated to create a complete liquid packaging line.

Built in Karmelle’s West Yorkshire workshop, the in-line filler features hygienic pumps, which are quick-strip to ensure ease-of-cleaning. Volumes can be easily adjusted using a hand-wheel and digital scale, and the control system accessed via an HMI screen.

Making its show debut, the fully automatic ‘T’ cork capper is designed to place and insert corks into bottles. Again, its controls are accessed via an HMI touch screen. Ideal for distilleries, this machine can be used to automate an otherwise labour-intensive process.

Finally, visitors will be able to take a closer look at one of Karmelle’s front-and-back labelling machines.

Peter said: “Karmelle are renowned for their efficient and reliable stand-alone machines – but, since bringing every stage of our manufacturing process in house, we’ve been able to provide complete liquid packaging solutions for a range of customers.

“We’re looking forward to telling visitors more about our turnkey lines at PPMA this year.”

Find Karmelle Ltd on stand D46.

For more information, please contact Rosie Crampton on 01484 533356, or email karmelle@gmail.com.