Cosmetics White paper
Special modules become standard
During the development of the MODULINE, standardization was one of the primary goals. Technology that was reserved for specialized engineering until recently, has been introduced to serial production as a modular system. As a result, the MODULINE offers solutions for specific customer requirements from the cosmetics and chemical industry – without additional development costs! This also means that standard modules are now equipped with special features.
Published in o-com consumer/nonwovens 02/2011
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To safely remove particles from jars, bottles and other objects, the blowout module with a combined suction unit was developed. The de-ionized air compensates for static electricity. The dispersed particles are suctioned and retained in a filter. Hence, a turning device is not needed; and containers are transported in an upright position.
Filling modules for many applications
Liquids such as perfume are best dispensed by a rotary pump or flowthrough meter cells (IDM, MDM). By completely replacing the dosing unit with a trolley system, product change is possible within three minutes. Pump stroke, pump rotation, filling needle and transversal pushing of the dosing unit are servo-driven.
For filling, the filling needle dives into the object. Depending on the filling system and the piston diameter, dosing volumes range from 2.5 to 550 ml. For filling viscous liquids such as cream, we recommend the use of piston pumps with a pneumatic seat valve. To prevent air bubble formation during the filling process, a rotation of the jars during filling can be integrated, if desired. A CIP unit is also available for cleaning, and formats and servo drives comply with the above properties.
Mascara requires special technical treatment to achieve desired filling results. The module comes with a piston pump with rotary valve, which is heated by a water circuit. In order to significantly reduce the forces acting on the product, i.e. pressure and shear forces, Optima Consumer has come up with a little trick: During filling, the mascara tube is lifted, which allows replacing the flexible hose between the piston pump and filling needle by a fixed pipe. Changeover of the entire dosing unit is carried out by a trolley system, which allows product change within three minutes.
Weight control and sampling
Manual random sampling is unnecessary with the weighing module. The objects are removed from the puck and transferred to weighing cells. After weighing, the objects are returned to an empty puck two cycles later. The net weight is calculated from the set tare weight and real gross weight. This Trolley system for product change process is followed by an automatic weight correction of the upstream filling systems. Depending on the version, testing of up to 25 % 50 % of all products is possible. The weighing range, for which different weighing cells are used, ranges from 50 to 500 g.
Closing, sealing and plastic welding In many applications, a foil lid is welded-on in addition to the screw cap. For this function, special modules are available. The lid can be pre-inserted in the cap. Or the lid is cut out and placed onto the container by a servo driven mechanism: The first module cuts out the coated aluminum lid. If desired, a pull tab can also be included. Pre-cut lids can be delivered from a magazine module by a pick-and-place system.
For extra security, the placed lid can be tack welded in place. As an “extra”, the placed lid is attached. The magazine of the module for the foil lid can be refilled on the fly. The module supports processing of containers with a diameter up to 95 mm.
In the next step, the foil is sealed. Plastic containers are sealed in a single step, glass jars in two steps. By integration of additional sealing heads, machine output can be doubled without structural changes from 60 to 120 units per minute. All sealing parameters - pressure, temperature and sealing time - are set via HMI. In addition, a format size change is carried out via the operator panel - without manual intervention. A special “revolver magazine” contains two sets of four sealing format plates.
Plastic components are welded by ultrasonic generators. This plays an important role in the production of air and water filters, where multiple components need to be safely assembled.
Incorporation of manual work stations
Format parts do not always pay off. When processing only small numbers, for example when new products are developed, containers from the rake transport of the MODULINE can be supplied on a conveyor system with integrated manual work stations. For this process, the containers - still inside the pucks – are pneumatically discharged. After manual processing, a servo drive returns the containers into the transport system of the MODULINE.