Filling and Capping Monoblock line for Hair Care

Project Description

Filling and Capping Monoblock for Hair Care applications, for instance Shampoo, Hair Conditioner and Bath Gel at 150 bottles per minute. The line does not require the use of pucks.

shampoo

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What was Client's need?

Our customer already had other low-medium speed lines (linear fillers) running at similar speeds with a low efficiency level, accuracy and large footprint. Long accumulations between the stand-alone Filler and Capper.

Our Value Proposition was based on reduction of production cost, reduction of the machine footprint, reduction of product waste after each product changeover and reduction of overfiller and undefiled bottles in every micro-stop of the line.

How did Mengibar solve it?

Thanks to our expertise in filling and capping monoblock for hair care, we designed a small size Monoblock with only 9 filling stations by Mass Flowmeters and 4 Capping stations for snap-on oriented caps. A vision system inspects each cap and the final orientation just before the cap inserting is done in the capping stations: caps not oriented correctly are rotated 180º.

Despite the size of the Monoblock, this unit includes all advantages of larger machines: smart product flow control, enhanced accuracy, quality 4.0 and industry 4.0.

Savings:

  • OEE improvement (complete line) 60%
  • Potential increment of production per year: 9.300.000 bottles (1 single shift)
  • Overall improvement on accuracy versus other flowmeter or net weight filling systems: 33%
  • Savings in product per year: 10 TONS