1. Client Overview
The client is a cosmetics manufacturer in Colombia. In addition to its own brands, the company has long provided R&D and manufacturing services for high-end lipsticks, makeup pencils, and eye makeup products for globally renowned luxury brands such as Dior, Chanel, Lancôme, and YSL.
With the explosive growth in global demand for “squeezable mascara” as an emerging packaging format, the client followed the trends of international beauty brands and sought to locally launch a disruptive new squeezable mascara product. Because this innovative product fundamentally differs from the traditional production process used for rigid plastic bottles, the client urgently needed a high-speed, fully automatic tube filling and sealing production line with a high degree of customization capability.
2. Client Challenges
During the requirements communication process, we identified the following challenges:
High-Viscosity Product Prone to Stringing and Buildup During Filling (resulting in raw material waste)
Compared with ordinary creams, mascara is more viscous and has extremely strong adhesion. A traditional tube filling and sealing machine is prone to “stringing,” “dripping,” and product residue on the tube tail during filling, resulting in a high product rejection rate and poor heat sealing at the tube end.
Multi-Size Compatibility and High-Precision Requirements (difficulty accommodating multiple specifications)
The new product line needed to perfectly accommodate a wide range of round tubes from 5 ml to 150 ml. Furthermore, because the client manufactures products for top luxury brands, extremely high standards were required for filling accuracy, tube alignment (color-mark detection), and automatic rejection of defective products.
3. Our Solution
We developed a customized solution based on the client’s specific requirements.
Solution details:
Providing the Appropriate Equipment
We provided a [Fully Automatic Servo-Driven High-Speed Tube Filling and Sealing Production Line], with a designed capacity of 60–75 tubes per minute.
Customized Design for High-Viscosity Products
Based on the characteristics of mascara formulations, we recommended a “pressure-feed loading system” and an “anti-tailing cut-off filling nozzle,” effectively eliminating stringing and reducing material waste.
Machine Structure Optimization
We upgraded the system with an intelligent inverted-tube detection and rejection system, as well as an intelligent color-mark detection and automatic defective-product rejection system, ensuring the correctness and integrity of every sealed finished tube while reducing the rejection rate.
Flexible Multi-Size Compatibility
The machine is equipped with quick-change, high-precision tube molds, allowing rapid format changes between 5 ml and 150 ml specifications. This perfectly accommodates the client’s production model involving multiple brands, small batches, and frequent production runs.
4. Key Highlights
Outstanding Customized Engineering Capabilities
From the anti-tailing servo filling system to the specialized hot-air sealing process for rounded tube ends, the project demonstrates our strong engineering capabilities in specialized cosmetic packaging applications.
Process Standards Aligned with International Luxury Brands
The solution was designed to comprehensively align with the process standards of international luxury brands such as Dior, successfully meeting the client’s stringent requirements.
High Automation and Low Material Loss
The entire production line—from tube loading, cleaning, alignment, filling, and sealing to finished-product rejection—is fully automated, reducing labor costs by more than 70% while minimizing the loss of high-value cosmetic raw materials.
High Cost-Effectiveness and Rapid Response
Facing competition from similar European equipment, we won the unanimous recognition of the client’s decision-makers through a highly competitive, cost-effective solution and our extensive professional experience in cosmetic machinery.
5. Project Results
Solution Approved Beyond Expectations
With our expertise in handling products such as squeezable mascara, lotions, creams, and various cosmetic formulations, along with meticulous attention to processing requirements, the solution successfully met and passed the client’s rigorous evaluation.
Rapid Completion of Compliance Documentation
Within one week, the client promptly issued and signed the Supplier Code of Conduct. Governed by German law, officially adding our company to its global list of core compliant suppliers.
Successful Transition to the Production Stage
The client has now quickly confirmed the final commercial contract and successfully paid the initial deposit. The project is currently awaiting the shipment of sample tubes. For actual product testing, they officially entered the high-standard customized development and precision assembly stage.
6. Client Feedback
No feedback available yet.
7. Future Potential
Potential areas for long-term cooperation include:
- Automation upgrades
- Full-line expansion
- Collaboration on new product lines
- Higher-capacity solutions
