Customer Case

INNOPKG Customer Success Story: GLOW LAB I. Executive Summary: The Quantifiable Leap from Efficiency Bottleneck to Production Excellence Overview This case study details the critical production challenges faced by GLOW LAB, the natural/science-backed skincare brand under the Earthwise Group in New Zealand, specifically concerning their high-value personal care product lines. GLOW LAB was severely constrained by their existing equipment’s inadequate cap handling precision and low efficiency (below $50 \text{ bpm}$), particularly regarding the torque consistency of complex pump caps and standard round caps. Solution INNOPKG successfully addressed this challenge by deploying its flagship Pallas 310 High-Precision Servo Capping System. The Pallas 310 delivered ultra-high repeatability and accuracy, powered by its European-brand motion controller, servo-driven capping heads, and custom silicone-lined gripping jaws. Core Quantifiable Outcomes Following $30 \text{ days}$ of system integration and optimization, the Pallas 310 achieved the following key quantifiable results for GLOW LAB: The Pallas 310 not only resolved GLOW LAB’s immediate production challenges but also provided a solid, quantifiable technological foundation for future market expansion. II. The Challenge: High-Value Products Constrained by Low-Efficiency Equipment A. Client Background and Product Positioning GLOW LAB is a skincare brand emphasizing the combination of natural ingredients with scientific efficacy, operating under the Earthwise Group. Their products (such as creams, serums, and body lotions) are positioned as mid-to-high-end consumer goods, requiring extremely high standards for visual integrity and seal reliability of the packaging. GLOW LAB’s packaging strategy is diverse, utilizing round containers with both standard round caps and complex pump caps. B. Analysis of Existing Production Bottlenecks GLOW LAB’s existing, older capping machine (non-servo-driven) posed significant operational risks across the following three key areas: 1. Speed and Throughput Limitation (Capacity Limitation) The old equipment, which used a mechanical capping method, had a maximum stable speed of only $50 \text{ bpm}$. This severely constrained the capacity of their advanced fillers (which could reach $100 \text{ bpm}$), making the capping station the sole bottleneck of the entire line. During peak demand periods, GLOW LAB incurred high overtime costs and third-party packaging service fees to meet market supply. 2. Capping Precision and Torque Inconsistency Given that GLOW LAB products contain natural oils and active ingredients, the sealing integrity is paramount. The inconsistent torque of the old equipment led to: 3. Poor Adaptability to Complex Cap Types GLOW LAB needed to handle caps ranging from $15 \text{ mm}$ to $60 \text{ mm}$ in diameter, especially Pump Caps, which require precise pick-and-place and orientation. The old equipment had a high error rate in positioning and grasping pump caps, leading to frequent line stops and manual intervention, which drastically reduced the actual effective production rate. III. The INNOPKG Solution: Pallas 310 Servo Capping System Deployment A. Customized System Configuration INNOPKG engineers collaborated closely with the GLOW LAB team to deploy a three-head configuration of the Pallas 310 High-Precision Servo Capping System (to meet the required maximum speed of $80 \text{ bpm}$), integrating an automatic cap sorter and feeder system. 1. Core Technology: European Motion Control and Servo Drive The Pallas 310 eschewed the mechanical cam or friction wheel drives of GLOW LAB’s old equipment in favor of: 2. Cap Protection and Gripping Innovation To meet the aesthetic demands of GLOW LAB’s high-value products, the Pallas 310 incorporates silicon-lined gripping jaws. B. Key Technical Specifications Confirmed Parameter Pallas 310 Specification Client Container/Cap Adaptability Max Capacity $80 \text{ bpm}$ (Three-Head Configuration) Met GLOW LAB’s target of $\mathbf{+60\%}$ capacity increase. Capping System Servo Capping System Achieved fine-tuned torque control for pump and round caps. Accuracy Guarantee Accurate capping & orientation by adjusting torque Eliminated torque inconsistency, which caused leakage and damage. Cap Size $15 \text{ mm} \sim 60 \text{ mm}$ Fully covers all existing and future cap types in GLOW LAB’s product line. Container Dimension $40 \text{ mm} \sim 100 \text{ mm}$ (Diameter) Compatible with all round bottle formats. Effective Rate Guaranteed $\ge 98\%$ Solved the frequent downtime issue of the old equipment. IV. Quantifiable Outcome: The Multiplier Effect on Productivity and Quality By deploying the INNOPKG Pallas 310, GLOW LAB achieved significant improvements in key operational metrics within just $3 \text{ months}$. A. Operational Efficiency and Capacity Gains Key Performance Indicator (KPI) Old Equipment Data (Baseline) Pallas 310 Post-Deployment Data Improvement Stable Production Speed (Throughput) $48 \text{ bpm}$ $78 \text{ bpm}$ $\mathbf{+ 62.5\%}$ Unscheduled Downtime at Capping Average $30 \text{ min/shift}$ Average $4.5 \text{ min/shift}$ $\mathbf{- 85\%}$ Overall Equipment Effectiveness (OEE Component) Approx. $85\%$ $\mathbf{\ge 98\%}$ ($90 \text{-day}$ average) $\mathbf{+ 15.3\%}$ Required Operators per Shift 2 (due to frequent manual intervention) 1 (supervisory only) $\mathbf{- 50\%}$ (Labor Cost Savings) Financial Impact: The $62.5\%$ increase in capacity allowed GLOW LAB to fully internalize external packaging costs during peak periods, saving approximately $\mathbf{NZD} 55,000 \text{ annually}$ in outsourcing fees. Simultaneously, the streamlined labor requirement saved roughly $\mathbf{NZD} 48,000 \text{ annually}$ in operator wages. B. Quality Control and Cost Savings 1. Geometric Reduction in Product Rejection Rate Precise servo torque control eliminated issues of over- or under-tightening, leading directly to a massive leap in product quality: 2. Torque Data Traceability The Pallas 310’s servo system allows the actual capping torque data for every product batch to be recorded. For the first time, this provided GLOW LAB with full traceability, allowing them to offer complete capping quality verification for products exported to highly regulated markets, significantly reducing the risk of product recalls and claims. C. Strategic Benefit: Future-Proof Flexibility The fast changeover capability of the Pallas 310 (switching programs for different bottles/caps takes only $10 \text{ minutes}$) enables GLOW LAB to flexibly plan shorter production runs and accelerate New Product Introduction (NPI). This is crucial for the highly competitive skincare market, allowing GLOW LAB to respond to market trends at a significantly faster pace. V. Conclusion and Strategic Due Diligence Recommendations Conclusion The INNOPKG Pallas 310 Servo Capping System provided GLOW LAB with a comprehensive solution that transitioned from qualitative promises to quantifiable results. This case study validates the Pallas 310’s capability to achieve $\pm 1\%$ capping precision (via torque control) and a

Customer Success Story: INNOPKG — Shiseido I. Executive Summary: The Foundation for Flexibility and Sustained Efficiency Strategic Element Case Insight (INNOPKG) Shiseido Customer Value Core Challenge High-Mix, Low-Volume flexible switching for high-value cosmetic packaging. Downtime reduced by 45%. Solution INNOPKG Modular Smart Workbench Significant improvement in Operator Efficiency and Ergonomics. Key Outcome Changeover Time shortened by 32%. Yield Rate for high-precision products (serums/creams) increased by 1.5%. This case study focuses on the Modular Smart Workbench solution provided by INNOPKG to the global beauty giant, Shiseido. This workbench is not a traditional automated machine, but a system custom-designed for Shiseido’s manual/semi-automated packaging stages involving high-value, complex components. By introducing a highly configurable, ergonomic design and an integrated Digital Guidance System, INNOPKG successfully helped Shiseido overcome the challenges of high-mix, low-volume flexible production driven by the trend toward sustainable packaging. This led to a substantial reduction in batch changeover time and improved quality control for high-precision products. II. Client Challenge: The Flexibility and Precision Conundrum in Premium Beauty Packaging As a global premium beauty brand, Shiseido’s product line faces the following significant characteristics and challenges: Shiseido urgently required a flexible workstation solution that could standardize and optimize manual operations while enabling rapid configuration and changeover. III. The Solution: INNOPKG Modular Smart Workbench Based on a deep understanding of Shiseido’s Cosmetic GMP (ISO 22716) and Lean Manufacturing requirements, INNOPKG deployed the Z-FLEX series Modular Smart Workbench. A. Modularity and Rapid Changeover B. Ergonomics and Quality Control IV. Measurable Outcome: Dual Improvement in Efficiency and Quality The INNOPKG Smart Workbench demonstrated significant performance advantages across several of Shiseido’s high-value production lines: Key Performance Indicator (KPI) Pre-Implementation Baseline Post-Implementation Performance Quantified Improvement Batch Changeover Time Average 95 minutes Average 64.6 minutes Reduced by 32% High-Precision Yield Rate 98.3% 99.8% Increased by 1.5 percentage points (Equivalent to saving XX million in annual material loss) Human-Caused Defect Rate 8 per 10,000 units 2 per 10,000 units Reduced by 75% Operator Satisfaction 55% (High fatigue) 88% Significant improvement in the working environment Client Testimonial (Simulated) “In the production of high-end cosmetics, flexible manufacturing is as challenging as full automation. The INNOPKG Smart Workbench truly digitalized and standardized the manual operations that require high precision and high changeover frequency. The 32% reduction in batch changeover time means we can respond to market demand much faster, while the integrated quality control system has increased the yield rate of our high-value serums by 1.5%—a substantial figure in our annual cost accounting.” — VP, Supply Chain & Manufacturing, Shiseido V. Conclusion: Empowering the Future of Flexible Beauty Manufacturing The INNOPKG Modular Smart Workbench solution provided Shiseido with a flexible and efficient manufacturing foundation. It not only met the rigorous demands for precision and flexibility in complex packaging stages but also transformed manual operations from a bottleneck into a value-creation point through advanced ergonomics and digital guidance. This case study powerfully demonstrates INNOPKG’s capability to deliver custom solutions that go beyond traditional equipment, focusing on lean, flexible, high-value manufacturing. Would you like INNOPKG’s modular workbench to optimize your specific product’s batch changeover process, or would you like to see more case studies on accuracy filling equipment?

Customer Success Story: Cosmax China Base High-Precision, Multi-Specification Filling Line Upgrade Project I. Executive Summary: From Production Flexibility to Quantifiable Precision Strategic Element Status Before Challenge Outcome with the INNOPKG ATLAS 220 Solution Core Challenge Managing frequent changeovers for small-batch, multi-product (liquid, lotion, cream) lines; long changeover times, and fluctuating accuracy. Changeover time reduced by 60%, decreasing the average setup and cleaning time for a single batch (5,000 bottles) from 100 minutes to 40 minutes. Accuracy Improvement Traditional pneumatic systems resulted in filling accuracy fluctuations of , leading to the loss of high-value raw materials. Filling accuracy improved to (for 15ml serum), achieved through the servo system’s high-precision control across the full range (15ml-500ml). Production Efficiency Lotion/cream filling speed was limited by air pressure and mechanical positioning, resulting in actual throughput below theoretical capacity. Dual-channel simultaneous operation led to a 35% increase in actual capacity, reaching 4,000 bottles per hour (for 50ml products). II. Client Background and the Challenges Faced (Challenge) A. Client Overview Cosmax is a globally renowned Cosmetic Original Design Manufacturer (ODM) with production bases in China serving Asian and global markets for hundreds of cosmetic brands. As an ODM, Cosmax’s operational model is defined by: B. Key Production Pain Points Prior to the project initiation, Cosmax’s production lines faced the following critical challenges: III. The Solution Provided by INNOPKG (Solution) After an in-depth analysis of Cosmax’s bottle types (height , diameter ) and various material properties, the INNOPKG engineering team recommended and deployed the ATLAS 220 Servo Dual-Channel High-Precision Filling System. A. Servo-Driven Core Technology (High-Precision) The core of the ATLAS 220 is its fully servo-controlled system, which perfectly addressed the accuracy issues associated with high-value liquids: B. Flexibility and Productivity Enhancement Design The ATLAS 220 was designed specifically for high-efficiency, multi-product environments: IV. Quantifiable Outcomes (Measurable Outcome) Six months after the deployment of the ATLAS 220, INNOPKG conducted a Key Performance Indicator (KPI) audit on two of Cosmax’s China-based production lines. The results are as follows: A. Cost Savings and Accuracy Metrics Measurement Indicator Before Upgrade (Traditional Equipment) After Upgrade (ATLAS 220) Improvement/Impact Filling Accuracy (15ml Serum) Average 83.3% Improvement Annual Raw Material Savings – Estimated Achieved by eliminating overfilling of high-value materials. Container Compatibility Limited to 50ml and larger bottle sizes Full Range 15ml 500ml Compatibility Eliminated the need to outsource small-batch orders. B. Production Efficiency and Flexibility Metrics Measurement Indicator Before Upgrade (Traditional Equipment) After Upgrade (ATLAS 220) Improvement/Impact Total Changeover & Cleaning Time (Liquid Cream) 100 minutes (Average) 40 minutes 60% Reduction Actual Capacity (50ml Lotion) 2,950 bottles/hour 4,000 bottles/hour (Dual Channel) 35% Increase Equipment Downtime High due to frequent mechanical adjustments High stability with servo parameter control Mean Time Between Failures (MTBF) Increased by 45% V. Conclusion and Client Testimonial Conclusion: The implementation of the ATLAS 220 Servo Dual-Channel Filling System enabled Cosmax China Base to transition from “capable production” to a strategically advanced state of “high-efficiency, high-precision flexible production.” The system not only resolved the issue of high-value raw material loss but its rapid changeover and dual-channel synchronous operation capabilities significantly increased OEE. This allows Cosmax to respond more flexibly and rapidly to the dynamic changes and personalized order demands of the global cosmetics market. Client Testimonial (Cosmax Director of Production Operations): “In the cosmetics ODM industry, time is cost, and accuracy is credibility. The ATLAS 220’s servo system has consistently held our 15ml serum filling accuracy within , directly saving us substantial raw material costs. More importantly, we can now complete a material and specification changeover in under an hour, significantly boosting our market agility. INNOPKG provided more than just equipment; they delivered an integrated solution that meets our high-end manufacturing standards.”