The MicroFlex™ System features a standardized platform of components that can be
configured to produce food, beverage, aerosol and bottle cans, and is easily
adaptable for the utilization of aluminum or steel sheet. More importantly, the
system and its components have been specifically developed with flexibility in
mind, allowing for process efficiency, easy changeover, significant metal
savings and enhanced can quality. MicroFlex™ is designed to incorporate its
latest programmable necking technology as well as the newest changeover friendly
printing developments. Initial MicroFlex™ configurations are scaleable for annual
production of 150 to 250 million cans or bottles depending on product size and
specification, and capital cost-to-output is comparable with larger scaled
beverage and food can systems.
MicroFlex™ combines standard components like bodymakers and trimmers, which are
scaleable, with other flexible components such as washers, ovens and other
equipment designed by Omnitech engineers and produced by world class
manufacturing partners. In addition, KJO Systems, a joint venture between Kian
Joo Can Factory Berhad and Omnitech International Inc., will produce the unique
conveying and support systems as well as other technical components from its
regional base in Malaysia. KJO Systems will service MicroFlex™ lines and all
components in Asia and parts of the Middle East. MicroFlex™ is the perfect
platform for scaleable, cost effective production of D&I cans in all sectors,
particularly those which cannot utilize D&I because of huge volume and
investment requirements. The small scale production line is ideal for replacing
three piece welded can lines and impact extruded aerosol lines. MicroFlex™ offers
the flexibility to respond quickly to growth or market changes and would be
especially well suited to service remote locations or applications for
nonstandard sizes with medium volume demand.
MicroFlex™ does not represent a wholesale change to the D&I process. In fact it
replicates the D&I process so all of the advantages and knowledge gained from
the trillions of cans produced with this process are captured into smaller scale
lines. MicroFlex™ Systems represent the summation of the know how and can making
expertise of Omnitech International which created the designs of the systems and
created a new global, exclusive and competitive supply chain for components with
an emphasis on flexibility and cost rather than speed. Some proven technologies
from other industries were carried over on an exclusive basis and others were
designed from scratch. MicroFlex™ systems were specifically designed and
developed to break the industry’s current rule of economic scale by helping
customers in these markets to achieve nearly equal costs per can with about one
third to one half of the production volume and capital investment. Because of
its standardized and modular design, patented equipment designs and exclusive
supply chains, OII is in a unique position to offer the market small, flexible
and much less costly can manufacturing systems. And smaller scale plants can be
located much closer to fillers/packers for significant reductions in
shipping/duties costs. This also opens new opportunities in smaller markets
currently utilizing three piece can lines which are less capital intensive up
front but come at the expense of a higher recurring cost per unit produced due
to higher metal content. Metal savings alone can justify a healthy ROI in many
of these instances. It also opens unique opportunities for can lines that can
produce limited runs of specialized marketing designs where this has never
before been economically feasible with D&I lines due to the large initial
investment and their associated economies of scale.
Presently, there are no other competitive D&I systems available and along with
OII’s protected supply chains and patent access, there are significant barriers
to entry for others. Before MicroFlex, the only D&I technology investment option
available for can-makers and beverage/food packers was and still is very large
scale custom engineered systems. These systems combine equipment from multiple
vendors, require a very large investment (>$30 million), and are designed to
generate significantly higher volumes of production (800 million to 1 billion
containers) to achieve reasonable economies of scale. Other than OII, no single
industry supplier has consolidated the D&I know-how, small-scale equipment
design and supply chain, standardized engineering and install processes that are
required for a complete cost-effective and profitable small scale D&I line.
The key opportunity for MicroFlex™ is to fill this market gap. Because of the
large investment and scale, traditional D&I lines are generally located in large
market areas or simply do not serve markets other than beer or beverage.
Small-scale fillers/packers are forced to ship and often import cans adding
significant costs (often more than 5-10%) to their products. Beverage marketers,
especially those multi-nationals whose growth is significantly dependent on new
products, are not able to trial or introduce new products in creative metal
packaging using the high volume manufacturing facilities. MicroFlex™ also offers
a key competitive alternative to canmakers/fillers which make/use three-piece
food and impact extrusion aerosol cans in niche product markets. Although these
non-D&I technologies do produce low volumes, they are also burdened with higher
metal content, higher production costs, and potentially higher rates of
spoilage.
MicroFlex™ is sold in three base configurations: I, II, and III, for output
where the equipment is common to all applications. From this base configuration,
Omnitech offers standard “add on” packages for beverage, food, aerosol, and now
bottle cans. In many cases, these packages will be further customized to suit a
particular application in a particular location.
MicroFlex™ is now available for all types of cans including food, beverage, one
and two piece aerosol as well as bottle cans. In general, MicroFlex™ II allows
for 200-250 million cans per year depending upon can size and specification.
For food and beverage can applications, MicroFlex™ III allows for 300-350
million cans per year.
MicroFlex™ I will be available in 2009 for low volume applications, such as
aerosol cans, requiring 50-100 million cans per year.
Click Here to view the MicroFlex™ Scope of Supply Summary for Services and
Equipment. Specific applications, products, and project locations will determine
the scope and final cost. We look forward to developing a MicroFlex™ solution
for your application and in helping you evaluate the benefit of this technology
for your market.