American TV personality Tim Gunn is known for being a mentor on the reality series “Project Runway,” and for his catchphrase, “Make it work,” which he repeated to designers countless times on “Project Runway.”

Gunn’s catchphrase rings true even in the beverage industry, where packaging companies must adjust to SKU proliferation, which has impacted can filling and seaming equipment.

Barry Fenske, product manager of filling technology at Krones Inc., Franklin, Wis., explains that designing flexibility into fillers is crucial for today’s equipment.

“This allows for running several product types on the same filler,” Fenske explains. “There are machines that can run carbonated or non-carbonated beverages, hot or cold fill, all on one machine. With a filler/seamer bloc needing to be flexible, changeovers can be impacted, especially at the seamer when there is a lid diameter change.”

This is especially applicable to co-packers, he notes.

Jordan Crawford, product manager of filling and process technology at Waukesha, Wis.-based KHS Inc., says that SKU proliferation has significantly reshaped the landscape for can filling and seaming equipment.

“With the rise of health-conscious and sober-curious consumers, beverage producers are diversifying their product portfolios to include functional drinks and non-alcoholic adult beverage alternatives,” Crawford explains. “Each of these products often comes with unique formulation requirements and stricter hygiene standards. This shift necessitates adaptable equipment capable of rapid changeovers between different SKUs while maintaining the highest hygiene standards.”

Tommaso Tegoni, product manager, filling at Norcross, Ga.-based Sidel, shares similar insights regarding the need for modern equipment.

“As market demand grows for diverse sizes and an expanding range of SKUs, the need for flexible and adaptable equipment has become more critical,” Tegoni says. “Modern systems must now facilitate rapid changeovers while accommodating carbonated and still beverages, as well as hot and ambient-filled products — all while minimizing energy, water, chemical, and raw material usage.”

Package size variances also influence can filling and seaming equipment.

“The rapid increase in SKUs has heightened the demand for enhanced automation and efficient changeover capabilities, making these features essential for modern filling and seaming equipment,” Tegoni notes.

Krones’ Fenkse says that the company’s can fillers are capable of handling a variety of cans on the market with some additional change parts. This makes the company’s canners attractive to co-packers as well, he says.

“Again, changeovers will take longer, and if the end-user wants to run a slim, standard and King can,” Fenkse shares. “The filler/seamer height adjust range needs to be reviewed, as well as lid feeders, as some cannot run all the sizes on one unit. This makes faster changeover times a key part of the requirements for the equipment.

“Further tool-less changeover development and lightweighting of parts that must now be handled by operators at handles by operators at higher frequency,” he continues.

KHS’ Crawford notes that the growing variety of package sizes and formats creates scheduling and operational challenges for beverage-makers.

“Frequent changeovers between different can sizes and product types can lead to significant downtime, impacting overall equipment effectiveness (OEE),” he says. “Our filling and process solutions are designed to facilitate quick and seamless transitions between different formats and flavors, allowing beverage producers to achieve higher throughput while maintaining flexibility.”

Other beverage market trends are affecting filling and seaming equipment. Krones’ Fenkse says that more sensitive beverage are moving into cans, which has impacted the equipment.

“Beverages that normally are packaged by aseptic PET lines might move their way to cans,” he shares. “Thus, an aseptic can filler/seamer will need to be explored. The issue is making the seamer aseptic, which is a tall challenge.”

Another trend Fenkse notes is decorative shapes and PET containers with can lids.

Meanwhile, KHS’ Crawford highlights the need for differentiation in the increasingly competitive market.

“Beverage producers are exploring unique formulations and packaging designs to stand out on shelves,” he says. “This trend has led to a demand for versatile canning lines that can handle multiple product types — from carbonated soft drinks to craft beers and functional beverages — on a single line. As a result, canning equipment must be highly adaptable, allowing for quick reconfiguration and minimal downtime.”

Sidel’s Tegoni lists the following trends: customization and variety, sustainability, premium and functional beverages, textural innovations, and hybrid beverages.

“The demand for personalized products, including limited-edition flavors and unique packaging, requires equipment that can handle frequent and efficient changeovers between products types and can sizes,” he explains.

Tegoni says that consumer preference for eco-friendly products requires equipment that is eco-friendly and sustainable packaging options. Additionally, the rise of high-end, health-focused beverages demand equipment capable of maintaining precise product quality and hygiene standards, he notes.

“Innovations such as nitro-infused drinks, jellies, and purees in beverages require filling systems that can handle varying viscosities and ensure consistent product delivery,” Tegoni says regarding textural development.

The increasing popularity of fusion drinks has also impacted filling and seaming equipment, he shares, as it requires versatile equipment that can manage different product characteristics, from carbonation to high acidity.

“The growth of craft breweries, hard seltzers, and specialty drink producers necessitates equipment that supports flexible production at smaller scales without sacrificing efficiency or quality,” Tegoni adds.

Considering can filling and seaming equipment

Before selecting can filling and seaming equipment, there are certain factors to acknowledge, especially in terms of flexibility.

Krones’ Fenske says that, for can filling, it is becoming popular to discuss having two seamers bloc’d to one can filler to help in changeover times for lid diameter changes.

“Also, handling parts on the fillers need to be a quick change, and separate recipes in the PLC for each SKU brought up at the touch of a button with very little fine-tuning required after changing to another SKU,” he suggests. “The machines should be flexible in running various package sizes, as well as various products and filling temperature considerations.”

Fenske also says to consider electrical flexibility for customers that might have multiple locations with varying power and utility demands and supplies.

Similarly, KHS’ Crawford states that flexibility is a “critical factor” when selecting can filling and seaming equipment, especially in a market that is characterized by rapid SKU proliferation and changing consumer preferences.

“One of the most important considerations is the integration of all system components — from filling and seaming to inspection and packaging,” he shares. “Each system must work together flawlessly to ensure efficient and consistent production. This level of integration not only reduces the risk of bottlenecks, but also enhances overall system performance.”

Sidel’s Tegoni notes that the company’s EvoFILL Can Filler is engineered to enhance beverage quality, optimize performance and boost flexibility. It was tailored to meet the needs of brewers and carbonated soft drinks (CSD) manufacturers in mind.

“This innovative can filler can handle CSDs at ambient temperatures and still drinks in hot-fill conditions, enabling the production of a wide variety of beverages with a single, versatile solution,” he says. “As manufacturers prioritize rapid changeovers, flexibility has become a critical factor in selecting can filling and seaming equipment.”

Tegoni states that Sidel addresses such demand with innovative solutions.

In terms of product safety being addressed in such equipment, Krones’ Fenske believes more checks and balances are necessary.

“You need a good can (check before rinsing, auto reject if out of spec), correct rinsing media for the application, low oxygen pick-up methods filler/seamer (flush the can at the filling valve with CO2/N2 prior to filling [and] blanket the can headspace with CO2/N2 prior to lid positioning), check for product fill height post seamer, [and] check the can downstream with an inspection device looking for slow leakers,” Fenske explains.

He lists lightweighting change of parts that are handled by operators, guarding evaluation, and adherence to any unique customer safety specifications to the facility as other safety considerations.

KHS’ Crawford considers product safety to be paramount, especially as the industry continues to innovate with new formulations and packaging formats.

“Ensuring product safety requires a holistic approach that considers all aspects of the production process, from raw materials to the final product,” he says. “The recent acquisition of HF Meyer by KHS and Ferrum underscores our commitment to enhancing our capabilities in this area. This acquisition strengthens our expertise in handling sensitive products, which require stringent hygiene controls.”

Crawford adds that, by addressing product safety at every stage of the production process, KHS helps beverage-makers maintain the highest quality standards.

“The product distribution architecture with an external static tank is best in class for cleanliness, minimizing live volume and contact surfaces with the beverage, while ensuring efficient mechanical action during internal cleaning (CIP),” Sidel’s Tegoni says. “Additionally, the reduced interface area between the beverage and counter-pressure gas helps maintain the beverage’s characteristics perfectly intact when processed by our filler. This architecture perfectly integrates with the [Sidel BlendFILL] mixer when required, allowing the mixer’s storage tank to be used as a filler tank, further reducing volumes and surfaces.”

As for what’s on the horizon for can filling and seaming equipment, Krones’ Fenske anticipates further development in hygienic filling and aspect filling products.

“Krones has come up with our most hygienic can filler yet — the Modufill Can Filler, which is available with Compact Clean Room design with a hygienically designed filler carousel and infeed module construction,” he says.

KHS’ Crawford feels that the future of this equipment is being shaped by multiple key technological advancements.

“One of the most significant trends is the increasing packaging of sensitive products in cans,” he says. “This trend requires advanced solutions that can maintain product integrity and prevent contamination. We are focusing on developing integrated systems that address all factors affecting beverage quality, including hygiene, oxygen management, and filling precision.”

Further, Crawford says automation and digitalization are playing an increasingly important role in the filling and seaming sector.

“For example, smart sensors and real-time data analytics enable manufacturers to monitor and control every aspect of the production process, ensuring consistent quality and reducing waste,” he notes.

Sidel’s Tegoni feels that digital advancements are transforming the landscape of can filling and seaming equipment. Cutting-edge technologies like predictive analytics, guided assistance, and self-adjustment are becoming essential, he notes.

“Self-adjustment, for instance, allows machinery to autonomously correct itself when production data indicates values are out of range,” he explains. “This capability also adapts manufacturing parameters in response to evolving production requirements, reducing reliance on human intervention and ensuring optimal performance in real-time.”

Regardless of what exactly is next for can filling and seaming equipment, beverage-makers must “make it work” in terms of shifting to meet consumer expectations while still providing quality products.