Case Packer for Cosmetic and Dermocosmetic Bottles

Company

A major player in dermo-pharmaceutical cosmetics wanted to automate the case packing of its large reusable pump bottles in order to make its end-of-line process more reliable and increase production capacity. The required solution had to be both flexible and scalable, capable of handling different bottle formats on the same installation. The customer also wanted to improve operator working conditions by eliminating repetitive movements and load carrying associated with case packing, while securing the overall process: correctly formed and closed cases, identification and traceability through labelling, inspection of non-conforming cases and smooth transfer of full cases to palletising.

Project & solution

To meet the customer’s throughput, flexibility and safety requirements, JYGA designed an automatic top-load RSC case-packing solution dedicated to large reusable bottles. The installation is integrated at the outfeed of an existing line: pump bottles are taken up on a conveyor and directed by a mechanical diverter into three lanes. At the end of the line, a batch of 12 bottles is formed and made available to the case-packing station.

At the heart of the solution, a multi-format automatic case packer handles the entire process:

• High-capacity case-blank magazine (stacks loaded manually),
• Positive RSC case forming using a vacuum destacker, controlled opening and transfer by a 2-axis manipulator,
• Bottom gluing followed by folding/pressing using a dedicated mechanical system,
• Transfer of cases on a lug chain, ready for filling and then top closing.

Case packing is carried out by a robot fitted with a gripper specially developed for this project. This tooling provides excellent format flexibility: fast adjustments, adaptation to different bottle diameters and heights, without major tooling changes. The batch of 12 bottles is picked and gently placed into the case, taking into account the constraints of reusable bottles and pumps while ensuring pack stability. Once full, the case continues along the lug chain for top closure by gluing.

At the outfeed, cases are discharged onto a roller conveyor for labelling. The solution can integrate a labeller and code-readability check, followed by a weighing module for weight control. Non-conforming cases (weight, label or flaps) are automatically diverted to a gravity roller table, while conforming cases are sent in line towards the palletising area.

The complete system is controlled via an ergonomic touchscreen human-machine interface, allowing recipe-based format changes and monitoring of alarms, counters and diagnostics. The machine is fully guarded by a secure frame with hinged and sliding doors.