Tetra Pak collaborated with a renowned beauty manufacturer to enable flexible production with reduced batch times – and considerable energy savings.
Before working with Tetra Pak, this prestigious global beauty producer used a traditional cosmetics production facility. As such, it required a significant amount of heating during the production process. In addition, as the manufacturing unit did not contain a vacuum function, the unit was typically left overnight in order to remove most of the air.
This is significant, as the presence of air will create bubbles in the final product. These bubbles increase the oxygen content, which has the potential to oxidize active ingredients contained in the formulation. If this occurs, it will destabilize the product.
The presence of bubbles in a formulation also increases its volume at the same mass, reducing the density of the formulation. Filling machines operate based on a volumetric principle, a quantitative analytical method. Therefore, when bubbles exist, the product quantity that has been calculated to accurately fill containers, bottles and packaging will be unstable.
From a marketing perspective, bubbles are also unwanted, particularly in transparent packaging, as consumers perceive these items as lower quality than their counterparts that do not contain bubbles.
The impact of this on both the brand and its consumers was three-fold:
- Leaving the formulation stagnant in the machinery for hours at a time, aged the mixture inside the machinery, reducing its overall quality.
- Its limited capabilities slowed batch times
- These had a detrimental impact on the speed the cosmetics producer was able to answer consumer demands for new trends.
Aim: improve everything
Ultimately, the beauty company was looking for a way to improve its process efficiency, while maintaining optimum quality and brand reputation. It also needed to ensure minimal downtime as out-of-action units would have a direct effect on the company’s sales and market-leading position.
The cosmetics producer first came to Tetra Pak after exploring the pilot options at the Product Development Centre (PDC) in Jakarta, Indonesia. It needed a flexible, reliable and high-quality production facility that was able to create several tonnes of product throughout the year.
After exploring how the prestigious producer handled mixing and formulation numbers throughout the year, Tetra Pak invited the company to its PDC. There it was able to see first-hand and in real-time how its number of batches per day, per month and per year would be improved using patented CoDE3 technology and expertise from Tetra Pak.
Together, the producer and Tetra Pak discussed best practices to manage and reduce energy consumption. Often, discussions relating to the step-by-step processes and details introduce new ideas and novel ways to overcome existing problems. For example, Tetra Pak experts learned about the producer’s current dilution process and the problems they were experiencing when diluting ingredients at various temperatures. It became apparent that by using Tetra Pak machines, the need for direct dilution in the mixers could be removed, and therefore overall batch times reduced and production capabilities increased.
By providing recommendations on how to overcome production challenges and reduce batch times — all tailored to the specific needs of the global company — a production process was designed collaboratively.
No need to heat
Using CoDE3 technology from Tetra Pak, which utilizes a cold emulsification process, the beauty producer saves considerable minutes as it no longer needs to heat up the water in the process, which currently makes up 70% of the final product. This presents the customer with significant flexibility. It can now produce the same output per year as its previous unit, yet with fewer resources. Or equally, it can maintain the same resources and maximize the machine’s output.
Since the patented CoDE3 technology and mixing unit from Tetra Pak entered the customer’s production facility in 2008, the producer has made significant and consistent energy savings. Based on 1 tonne of skin care cream produced every year, this cosmetics name makes a saving of $22,800. This increases to $46,500 for 2.5 tonnes of skin care formulations and $70,500 for 5 tonnes.
“Customers today are looking for ways to stay ahead of the market,” says Martuani Siregar, Category Director, Tetra Pak. “This is a core focus for Tetra Pak too, and each year we examine our technology and product lifecycles to ensure our maintenance procedures are safe, reliable and answer the needs of our consumers and the wider industry.”