One solution for all products the cosmetics company kao is going with diversity when it comes to packaging its hair care products with the new "fp 181" filling platform from oystar iwk, tubes and products of various shape formats and product formulations can all be processed by one machine. Stutensee, june, 2012. Featuring renowned brands such as john frieda, kanebo or goldwell, the hair care assortment offered by kao is very diverse.
As such, the japanese cosmetics company&rsquos production capabilities need to be every bit as diverse and flexible in order to operate efficiently and profitably. The german subsidiary kao corporation gmbh has therefore decided to invest in a new tube filler for shampoo and conditioners, namely the fp 181 tube filling machine from oystar iwk. The fp 181 is a powerful and efficient machine that can be used for a variety of functions and purposes. At kao, the fp 181 produces 50 ml tubes with a performance of up to 120 strokes per minute as well as 250 ml tubes with a performance of up to 80 strokes per minute. &rdquothat&rsquos a peak performance, especially in light of how difficult it is to bottle this particular product&ldquo, emphasizes peter wrobel, plant manager at kao in darmstadteberstadt, germany. "the machine allows for the processing of up to fifty different product formulations as well as up to five base materials without any problem whatsoever." the fp 181 is also capable of processing metal and plastic tubes with a diameter of 10 to 60 mm and a length of 60 to 250 mm.
Troublefree processing at the beginning of the production process, the tubes are placed in a tube infeed system tzs and then furthered along to the tube filler. The tube inserting device makes use of a vacuum to remove one tube in each case from the feed chute and leads it to the tube holder. "this works because of a simultaneous swivel and rotation movement without any waiting periods", states mathias ponzelar from oystar iwk. "in addition, the tube inserter works in a curvesteered manner such that the tubes can be smoothly passed along to the fp 181." the tubes are then fed along to the various machine stations from the tube holder. They are positioned exactly in the respective work station with the aid of automatic height adjustment provided by the transport system.
At the next station, the filler, the tubes are gently lifted by a motion profile run by a servo motor in order to achieve a smooth, bubblefree filling process. In addition, the dosing station makes precise capacity settings possible via a servo motor piston pathway setting. "this guarantees kao a high level of process security", states mathias ponzelar of oystar iwk. "in addition, we were able to clearly reduce the downtime of the machine, because all of the parts coming into contact with the product can be exchanged without tools when the product is switched." the same is the case for the hot air head that is made use of during the ensuing welding of the tubes. This can also be exchanged without using tools when changing over to a new format, as can the press device that seals the tube afterwards. "regardless of which format or material we switch the fp 181 to, the tool changeover only lasts a few minutes in each work station", emphasizes peter wrobel of kao. During the sealing procedure, servoaligned scanning marks ensure that the tubes are sealed with the correct orientation.
Thanks to the heightadjustable transport system, the station only has to be adjusted to the various tube lengths. Before the tubes are then finally ejected from the machine through the tube discharge, they are trimmed for best optical appearance by the doublesided operated shear blades. Tube filler no. 4 the fp 181 is operated via the new "hmi" from the oystar group &ndash an ergonomically designed, futureoriented touch screen. Similar to an iphone, its use is intuitive and takes place via a modern multitouch system. Both the machine processes and any current messages are systematically presented on the 15.4" widescreen display from kao and are immediately recognizable.
"that makes it very easy to use", says peter wrobel. "we can then see all the information we need to while always maintaining a good overview." with the new filling platform, oystar iwk is further enhancing its strong business relationship with longterm customer kao. The cosmetics manufacturer is currently making use of three tfs series tube fillers at its plant in darmstadt, both for the production of hairdye and hair conditioning products. "each machine is running flawlessly and makes a considerable contribution to our productivity", sums up peter wrobel of kao. "featuring this versatile range of applications for our wide spectrum of products, the fp 181 machine is definitely the right choice for us." captions oystar fp 181kao 1 at kao, the fp 181 produces 50 ml tubes with a performance of up to 120 strokes per minute as well as 250 ml tubes with a performance of up to 80 strokes per minute.
Oystar fp 181kao 2 rainer bangert, teamleader filling at kao corporation gmbh in darmstadt. About oystar iwk iwk verpackungstechnik gmbh is a globally operating company in the oystar group with approximately 330 staff. The company manufactures and sells cartoning machines, tube filling and sealing machines, in addition to complete packaging concepts from a single source. The company&rsquos portfolio aims at applications for the pharmaceutical and cosmetic industries. A further focus is placed on the company&rsquos service business. Worldwide sales are supported by oystar&rsquos own sales and service companies in france, england, the usa, thailand, russia and china as well as commercial agencies throughout the world. About oystar group oystar &ndash the packaging group is one of the world&rsquos leading suppliers of packaging machinery, technology and services.
Oystar has extensive knowhow in the key industries of dairy products, food and consumer, as well as pharmaceuticals and cosmetics. Based in stutensee near karlsruhe, germany, the holding company currently represents 12 manufacturing companies as well as numerous sales and service companies. At present oystar holding employs a workforce of approximately 2,000 worldwide and generated a total of eur 404 million in sales in 2011.