Personal Care Line

Client Needs

The client required a complete and fully integrated line for the packaging of shampoos, conditioners and other personal care products.

The main challenge of the project was the wide variety of applications to be handled. The line needed to process products with different characteristics and viscosities while ensuring accurate and repeatable dosing.

At the same time, it had to handle 8 bottle formats and 7 different cap types, including closures with complex geometries requiring accurate torque control and, in some cases, precise final orientation.

The main requirements included:

• accurate filling of products with different viscosities;
• automatic handling of multiple bottle formats;
• high-precision torque control;
• handling of dispensers, screw caps, flip-top caps and oriented closures;
• automatic orientation of bottles and caps;
• high hygienic design standards;
• continuous labelling operations;
• complete line integration and synchronization.

The client was also looking for a single partner capable of managing the engineering, integration and centralized control of the entire production process.

The TorQ Packaging Solution

TorQ Packaging developed a complete turnkey line designed to ensure accuracy throughout the filling and capping stages, multi-format flexibility and production continuity.

The line begins with a bottle unscrambler equipped with two robots, designed to automatically feed the different bottle formats. The system detects the position of each container and corrects its orientation, ensuring that every bottle is properly presented to the subsequent stages of the process.

This function is particularly important in the personal care industry, where asymmetrical bottles and distinctive designs require accurate positioning.

The filling stage is handled by a TorQ Packaging electronic linear filler equipped with mass flow meters.

This technology provides accurate and repeatable dosing for products with different viscosities and properties. The system adapts the filling parameters to the specific characteristics of each product, maintaining consistent process accuracy and quality.

Electronic recipe management also simplifies the transition from one product or format to another, making production changeovers easier and allowing the line to accommodate a wide range of production requirements.

Particular attention was paid to the hygienic design of the filler, developed to facilitate cleaning, accessibility and the effective management of the processing areas.

The capping stage is handled by the TorQ Packaging EvoQ rotary capper, designed for applications requiring a high degree of accuracy and flexibility.

Its servo-controlled system enables electronic management of the closure parameters and applied torque, adapting the capping cycle to the specific characteristics of each cap and bottle.

The machine can handle different types of closures, including:

• dispensers;
• screw caps;
• flip-top caps;
• caps requiring precise orientation;
• closures with different geometries and gripping systems.

For oriented closures, a vision system identifies the cap position and enables the servo system to perform the rotation required to achieve the correct final orientation.

The combination of servo technology, torque control and vision systems ensures accurate and repeatable closure application, even in the most complex applications.

The capper was also developed according to hygienic design principles, contributing to a complete line that meets the standards required by the personal care industry.

The process continues with a rotary labelling machine equipped with a non-stop system designed to maintain production continuity. The line is completed by a shrink wrapper and a manual case-packing station, with provision for future expansion to a fully automatic system.

Key Strengths

• High-precision filling: electronic technology with mass flow meters.
• Handling of different viscosities: dosing parameters adaptable to the characteristics of each product.
• Servo-controlled EvoQ capping: accurate and repeatable torque control.
• Handling of complex closures: dispensers, screw caps, flip-top caps and oriented caps.
• Vision system: control of the correct final orientation of closures.
• High hygienic design standards: particular attention to the design of both the filler and capper.
• Multi-format flexibility: 8 bottle formats and 7 cap types handled on the same line.
• Automatic bottle orientation: bottle unscrambler with a dual robotic system.
• Non-stop labelling: improved production continuity.
• Scalable end-of-line system: designed for future integration of automatic case packing.
• Turnkey solution: a single partner for the engineering, integration and synchronization of the complete line.

Results

The new line enables the client to handle a wide variety of products, bottles and closure systems on a single production platform.

The filler ensures accuracy and repeatability even when processing products with different viscosities, while the EvoQ capper provides precise control of both torque and the orientation of more complex closures.

The integration of the different technologies creates a continuous and synchronized production flow, simplifying operations while maintaining high quality and hygiene standards throughout the process.

Conclusion

This project reflects TorQ Packaging’s approach to complete lines for the personal care industry: a single integrated system designed around the specific characteristics of the products, containers and closures.

The combination of electronic filling, servo-controlled capping, vision systems, robotic automation and hygienic design provides the client with an accurate, flexible and reliable solution capable of adapting to evolving production requirements over time.