Precision Star Wheels for Packaging Lines
Custom CNC machined star wheels with metal-detectable options for food safety compliance
- Xray and Metal-Detectable Options Available
- ±0.005" tolerances for sub-10 minute changeovers
- Rapid Turnaround & Lead Times
- Nearly 40 years of manufacturing excellence
Why Choose CDS Plastics Star Wheels
Metal-Detectable & X-Ray Detectable Options
Our metal-detectable and X-ray detectable plastic provides critical contamination prevention.
Precision Tolerances
We hold ±0.005" standard (±0.002" available) ensuring consistent pocket dimensions for rapid changeovers.
Material Expertise
From standard acetal to high-temperature PEEK, we choose the right material for your specific application.
Trusted Since 1986
Nearly 40 years of quality and reliability with engineering expertise and reverse engineering capabilities.
Solutions for Common Packaging Challenges
Our exact pocket dimensions and perfect compatibility through reverse engineering dramatically reduce downtime.
Relief angles and smooth transitions eliminate pinch points while providing superior cushioning.
Allows your detection systems to identify any fragments, preventing costly recalls.
Superior materials and precise tolerances significantly extend replacement intervals.
Metal detectable for metal detectors, X-ray detectable for X-ray systems, or ultra detectable for both. Fragments are caught before products ship, preventing recalls that could cost millions.
Technical Specifications & Capabilities
Machining Capabilities
- Diameter range: 3" to 24" (larger available)
- Thickness: 0.25" to 2.0"
- Number of pockets: 4 to 24 positions
- Standard tolerance: ±0.005"
- Precision tolerance: ±0.002"
- Surface finish: 63 Ra standard, Better available
Container Profiles
- Round bottles: Semi-circular with 5-15° relief
- Square containers: Small radii and overdrilled corners available
- Oval bottles: Custom matched geometry
- Cans: Specialized rim protection pockets
- Vials: Precision pharmaceutical specs
- Custom: Any container configuration
Material Selection Guide
| Material | Key Properties | Temperature Range | Best Applications |
|---|---|---|---|
| Acetal (Delrin®) | Low friction, excellent stability | -40°F to 180°F | Standard bottling, general packaging |
| UHMW-PE | Superior impact absorption | -260°F to 180°F | Glass bottles, delicate containers |
| Cast Nylon | High load capacity (4,000 psi) | -40°F to 250°F | Large containers, high-stress |
| Ultra Detectable Acetal | Detectable by all systems | -40°F to 180°F | Food processing, contamination-critical |
| PEEK | CIP/SIP resistant, sterilizable | Up to 480°F | Hot-fill, aseptic, extreme chemicals |
Industries & Equipment Compatibility
Food & Beverage
Bottling lines, dairy processing, sauce/condiment packaging. Container sizes from 2 oz to 1 gallon with metal-detectable options for food safety.
- Craft breweries
- Dairy processors
- Sauce manufacturers
Pharmaceutical
Vial handling, bottle filling, cap feeding systems. USP Class VI compliant materials with complete validation documentation.
- Vial filling lines
- Tablet bottling
- Cap inspection
Personal Care
Cosmetic packaging, chemical containers, automotive fluids. Custom solutions matched to your equipment requirements.
- Shampoo bottling
- Cosmetic jars
- Tube filling
Equipment Brands
Fillers: Krones, KHS, Sidel, Federal
Cappers: Fowler, Zalkin, Arol
Labelers: P.E. Labellers, Sacmi
Line Speeds
Supporting production speeds up to 2,000 containers per minute with consistent performance.
- Low: 50-200 CPM
- Medium: 200-800 CPM
- High: 800-2000 CPM
Container Types
Any configuration from 2 oz vials to gallon jugs, including specialty shapes and custom profiles.
- Round & square bottles
- Oval containers
- Cans & jars
OEM Equipment
Custom star wheels for original equipment manufacturers. Prototyping to production runs with precise tolerances and reverse engineering capabilities.
- Custom machinery builders
- Specialty packaging equipment
- Legacy part replacement
Material Handling
Durable star wheels for conveyor systems and material handling equipment. Wear-resistant materials for 24/7 operations with predictable replacement cycles.
- Distribution centers
- Sorting systems
- Assembly line conveyors
Ready to Optimize Your Packaging Line?
Get precision star wheels that reduce changeover time and eliminate contamination risks
What We Need for Your Quote:
- Container specifications (type, dimensions)
- Line speed requirements (CPM)
- Equipment manufacturer and model
- Current star wheel sample or drawing
- Quantity and delivery needs
No Drawings? No Problem.
We offer complete reverse engineering from your worn parts.
Frequently Asked Questions
How do I determine when star wheels need replacement?
Inspect for visible pocket wear, increased container jams, or product scuffing. High-speed lines should be checked every 6 months. Worn pockets cause progressively worse problems and can damage downstream equipment.
Can you duplicate star wheels without original drawings?
Yes, our reverse engineering process captures all critical dimensions from your sample part. We often identify original material and can offer improvements by identifying consistent part failures.
What makes X-Ray & Metal Detectable plastics important?
They allow your inline detection equipment to identify any plastic contamination before products leave your facility. This capability is becoming standard practice in food processing to prevent costly recalls and protect consumer safety.
