The following are the key pain points encountered in the production of cushion creams:
Difficulty in Filling High-Viscosity Liquids: Liquids with high viscosity (exceeding 15,000 mPas) are impossible to fill using conventional methods.
Even if filling is technically feasible, the poor flow properties of such liquids often lead to spillage during the capping and stacking processes, resulting in high defect rates and low operational efficiency.
Low Filling Accuracy: Filling accuracy is often compromised. Liquid spillage during the capping stage leads to high defect rates, increased rework requirements, and elevated labor costs.
Manual Labeling: The labeling process cannot be automated, necessitating a large workforce to apply labels manually-a highly inefficient practice.
Low Production Output: It is difficult to accelerate the production pace. Output can only be increased once workers have attained a high level of proficiency.
Currently, production output typically ranges between 800 and 1,000 units per hour, making further increases extremely challenging.
Inability to Achieve Full Automation: From the placement of the cushion insert to labeling, capping, and packaging, a single production line requires a team of over 10 workers to operate, resulting in an extremely high labor intensity.
To address these pain points, we-as a professional manufacturer of automated machinery-have developed a fully automated BB/CC Cushion Filling Machine. This system offers the following distinct advantages:
Filling Capabilities: The machine utilizes three simultaneous filling heads, achieving a filling efficiency of up to 1,800 units per hour. It supports multi-color filling, accommodating a selection of 1 to 3 distinct colors.
Furthermore, it can execute filling patterns precisely according to customer-designed specifications, free from limitations regarding color arrangement or geometric shape.
Expanded Material Compatibility: The system is capable of filling liquids with viscosities exceeding 40,000 mPas and handling sponge inserts with surface area densities exceeding 50 kg/m².
This capability represents a significant breakthrough, effectively removing previous limitations on product formulation design.
High-Precision Filling Mechanism: The filling mechanism for the cushion inserts employs ceramic pumps, which are easy to clean and maintain consistent filling accuracy over time. Filling errors are strictly controlled within a tolerance of 0.2g.
Advanced Conveyance System: The machine utilizes a circular track conveyance system to ensure precise synchronization across all workstations. This system guarantees exceptional positional accuracy-controlled within ±0.05mm-whenever a workstation pauses.
This precise positioning ensures the perfect alignment of the filling heads, preventing liquid spillage during the subsequent ring-pressing stage.
Consequently, the system effectively resolves the issue of high defect rates historically associated with this process, achieving an impressive product acceptance rate of up to 99%.
Automatic Box Retrieval Unit: While ensuring that the inner liners remain free of defects-such as damage or scratches-a robotic arm automatically retrieves the assembled cosmetic boxes from the pallets traveling along the conveyor line.
The boxes are then placed onto an adjacent conveyor belt, ready for processing at the subsequent packaging workstation. This process significantly reduces both the time and labor costs associated with manual box handling.
Automatic Sealing and Labeling: Utilizing a fully automated, synchronized sealing and labeling mechanism, this system not only ensures labeling precision within a tolerance of 0.5 mm but also boosts production efficiency and lowers labor costs.
