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História de sucesso do cliente INNOPKG: LABORATÓRIO GLOW I. Sumário executivo: O salto quantificável do gargalo de eficiência para a excelência de produção Visão geral Este estudo de caso detalha os desafios críticos de produção enfrentados pelo GLOW LAB, a marca de cuidados com a pele natural/científica do Earthwise Group na Nova Zelândia, especificamente no que diz respeito às suas linhas de produtos de cuidados pessoais de alto valor. O GLOW LAB foi severamente limitado pela precisão inadequada do manuseio de tampas e pela baixa eficiência de seus equipamentos existentes (abaixo $50 \text{ bpm}$), 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: Palas 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. 4. 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 $3 \text{ months}$. UM. Operational Efficiency and Capacity Gains Key Performance Indicator (KPI) Old Equipment Data (Baseline) Palas 310 Post-Deployment Data Improvement Stable Production Speed (Throughput) $48 \text{ bpm}$ $78 \text{ bpm}$ $\mathbf{+ 62.5\%}$ Unscheduled Downtime at Capping Average $30 \text{ min/shift}$ Média $4.5 \text{ min/shift}$ $\mathbf{- 85\%}$ 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: O $62.5\%$ 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 $10 \text{ minutos}$) 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

História de sucesso do cliente: INNOPKG-Shiseido I. Sumário executivo: A Fundação para Flexibilidade e Eficiência Sustentada Elemento Estratégico Case Insight (INNOPKG) Shiseido Customer Value Core Challenge High-Mix, Comutação flexível de baixo volume para embalagens cosméticas de alto valor. Tempo de inatividade reduzido em 45%. Solução INNOPKG Modular Smart Workbench Melhoria significativa na eficiência e ergonomia do operador. Resultado principal Tempo de mudança reduzido em 32%. Taxa de rendimento para produtos de alta precisão (soros/cremes) aumentado em 1.5%. This case study focuses on the Modular Smart Workbench solution provided by INNOPKG to the global beauty giant, Shiseido. Esta bancada não é uma máquina automatizada tradicional, but a system custom-designed for Shiseido’s manual/semi-automated packaging stages involving high-value, componentes complexos. Ao introduzir um sistema altamente configurável, 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. Isto levou a uma redução substancial no tempo de troca de lote e melhorou o controle de qualidade para produtos de alta precisão. II. Desafio do cliente: The Flexibility and Precision Conundrum in Premium Beauty Packaging As a global premium beauty brand, A linha de produtos da Shiseido enfrenta as seguintes características e desafios significativos: Shiseido urgently required a flexible workstation solution that could standardize and optimize manual operations while enabling rapid configuration and changeover. III. A solução: INNOPKG Modular Smart Workbench Based on a deep understanding of Shiseido’s Cosmetic GMP (ISO 22716) and Lean Manufacturing requirements, INNOPKG implantou a bancada modular inteligente da série Z-FLEX. UM. Modularity and Rapid Changeover B. Ergonomics and Quality Control IV. Resultado Mensurável: Dual Improvement in Efficiency and Quality The INNOPKG Smart Workbench demonstrated significant performance advantages across several of Shiseido’s high-value production lines: Indicador-chave de desempenho (KPI) Pre-Implementation Baseline Post-Implementation Performance Quantified Improvement Batch Changeover Time Average 95 minutes Average 64.6 minutes Reduced by 32% Taxa de rendimento de alta precisão 98.3% 99.8% Aumentado em 1.5 pontos percentuais (Equivalente a economizar XX milhões em perdas materiais anuais) Taxa de defeitos causados ​​por humanos 8 por 10,000 unidades 2 por 10,000 units Reduced by 75% Satisfação do Operador 55% (Alta fadiga) 88% Significant improvement in the working environment Client Testimonial (Simulado) “Na produção de cosméticos de alta qualidade, a fabricação flexível é tão desafiadora quanto a automação total. The INNOPKG Smart Workbench truly digitalized and standardized the manual operations that require high precision and high changeover frequency. O 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, Cadeia de mantimentos & Fabricação, Shiseido V. Conclusão: 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. Este estudo de caso demonstra poderosamente a capacidade da INNOPKG de fornecer soluções personalizadas que vão além dos equipamentos tradicionais, focusing on lean, flexível, fabricação de alto valor. Você gostaria que a bancada modular do INNOPKG otimizasse o processo de troca de lote do seu produto específico, or would you like to see more case studies on accuracy filling equipment?

História de sucesso do cliente: Cosmax China Base de alta precisão, Projeto de atualização de linha de enchimento multiespecificações I. Sumário executivo: Da flexibilidade de produção à precisão quantificável Status do elemento estratégico antes do resultado do desafio com o INNOPKG ATLAS 220 Desafio principal da solução Gerenciar trocas frequentes para lotes pequenos, multiproduto (líquido, loção, creme) linhas; longos tempos de mudança, e precisão flutuante. Tempo de mudança reduzido em 60%, diminuindo o tempo médio de configuração e limpeza para um único lote (5,000 bottles) from 100 minutes to 40 minutos. 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) UM. 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 (Solução) 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. UM. 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: 4. Quantifiable Outcomes (Resultado Mensurável) 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: UM. Cost Savings and Accuracy Metrics Measurement Indicator Before Upgrade (Traditional Equipment) After Upgrade (ATLAS 220) Improvement/Impact Filling Accuracy (15ml Serum) Média 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 minutos (Média) 40 minutos 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) Aumentado em 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. Depoimento do cliente (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.”