The Challenge
Like many producers just getting started in cans, Smooth 42 bought a used canning system control startup costs. With mechanical skill and tenacity on their side, they figured they could get it running themselves. But the realities of used equipment and new system operation created early challenges:
👉 1 in every 4 cans were leaking due to seamer set-up challenges
👉 No seam tooling documentation or lid compatibility info
👉 Fill probes misfired, causing high product loss
👉 The Depalletizer was frequently jamming
👉 Sensor wiring was damaged and undocumented
They worked late nights trying to diagnose the issue. Adam tore down over 60 seams himself, purchased a digital scope, scoured manuals, and watched every video he could find. At one point, he was ready to hire a brewer from a nearby operation just to get a second set of eyes. What finally pushed them to reach out?
"We were two weeks behind on customer deliveries, working until 3am, and still leaking one in every four cans. It was either get the canning system to work or replace it entirely.” Adam, Owner @ Smooth 42
The Solution
Smooth 42 coordinated 3 days of on-site training and service wit Cask. A pre-training call helped them identify pain points, cover a training approach, and ensure spare parts were ordered for their specific use case. During training, Cask technical expert, Terry Farrell, spent in-depth time with their operators building system confidence, and were able to:
✔️ Identify and resolve lid incompatibility (mixed profiles in the same sleeve)
✔️ Install the proper seam roll dies and chuck for LOE (B64) lids
✔️ Calibrate seam rolls using proper first/second op theory and tolerance checks
✔️ Troubleshoot fill probe sensor and wiring errors
✔️ Solve Depalletizer challenges for smoother flow
✔️ Integrate their Chart Nitrogen Doser for non-carbonated RTDs
✔️ Installed changeover for Sleek can compatibility
"Customers often think training is just seam theory and cleaning tips. But training provides the critical foundation that makes the learning curve of packaging far less steep, and gives teams to tools they need to truly be successful out of the gate. It helps avoid the countless hours of troubleshooting going about it alone." - Terry Farrell, Technician @ Cask
The Results
Used equipment often comes with hidden costs. When customers skip training to save money, it can result in lost product and trust, unforeseen can and lid compatibility issues, stress and delays getting the system operational.
By the end of training, Smooth 42’s seams were fully in-spec. They're confident in diagnosing seam issues, manage lid profile compatibility, and adapt their line for nitrogen-dosed still beverages.
Their launchpad for canning RTDs is now a operation, and they're in a great space to continue expanding their operations with new locations and increased packaging speed.
