800–6,000 units/h

Cosmetics Filling Line

Cosmetics and pharmaceuticals: precise piston dosing of small volumes, handling bottles, jars, tubes and dispensers, a clean zone and full batch traceability.

Request a line quote Configure a line

Product: Creams, lotions, gels, serums, shampoos, ointments
Viscosity: up to 100,000 cP
Container: Bottle, jar, tube, airless, 5 ml – 1 L
Output: 800–6,000 units/h
Dosing: Servo-piston, ±0.5 %
Capping: Pumps, dispensers, flip-top, screw caps
Tube sealing: Hot air, trimming and batch embossing
Materials: AISI 316L, pharmaceutical-grade seals

About the solution

Cosmetic products are expensive and dose volumes are small, so priority goes to accuracy and zero waste. A servo-piston doser with an anti-drip valve holds deviation within ±0.5 % even at doses of 5–30 ml.

The line is built modularly: filling machine, pump and flip-top capping, tube filler with hot sealing, labeler and coder. For pharmaceutical products, a clean zone and validatable washing are added.

Built into the design

Precise small doses

The servo-piston meters from 5 ml with repeatability unattainable by gravity filling.

No product loss

Anti-drip valve and vacuum suck-back: costly formulations don't remain on the neck or soil the label.

Tube handling

Orienting the tube by its mark, filling, hot seam sealing, trimming and batch-number embossing.

Clean zone

Laminar flow over the filling zone, designed to GMP requirements for pharmaceutical products.

Line composition along the product flow

8 positions along the product flow. Every unit opens in the catalog: series, specifications, scope of supply and a quote request.

Full equipment catalog

Line model selection

Selecting a doser by product viscosity

Creams and thick emulsions require a piston doser; liquid products use diaphragm or gravity filling.

Product type	Dosing method	Dose range	Output
Cream, lotion, mask	piston, with heated tank	10–500 mL	1,500–3,000 pcs/h
Shampoo, shower gel	diaphragm pump	50 mL – 1 L	2,000–4,000 pcs/h
Foundation, serum	piston with precise dose	5–100 mL	1,200–2,500 pcs/h
Liquid soap, antiseptic	gravity or diaphragm	50 mL – 1 L	2,500–5,000 pcs/h

Dose accuracy for small containers (up to 50 mL) is ±1%, achieved through a precision piston pump and servo drive.

Container and packaging

Container material	Shape	Volume	Capping method
PET / PP / glass	round, oval jar	10–500 mL	screw cap, dispenser
Pump bottle	round, square	50 mL – 1 L	pump doser, spray trigger
Tube	cylindrical, laminate	30–200 mL	seal or flip-top cap

Format parts are designed for fast changeover between multiple SKUs within a single shift.

Operating conditions

Parameter	Value
Product-contact materials	AISI 316L, silicone gaskets
Product tank heating	up to 60 °C for viscous emulsions
Room temperature	18–28 °C
Power supply	380 V, 3-phase, 50 Hz

Line process flow

The cosmetics filling line is assembled around the specific product: creams and emulsions require a piston doser with a heated tank, liquid products need a diaphragm pump at high speed. The common part of the line is precise dosing of small volumes, capping with a pump or dispenser, and careful packing of small containers.

Key line features

Piston doser with heated product tank — viscous emulsion does not set in the piping
Dose accuracy for small containers (10–50 mL) of ±1% or better via a precision pump and servo drive
Dip nozzle with vacuum suck-back — no drips on the neck after filling
Quick-change format parts: neck grippers and starwheels for jars, tubes, and bottles
Product-contact parts in polished AISI 316L stainless steel with no stagnant zones
Compatible with any capping method: screw cap, pump, spray trigger, flip-top
Fill volume and cap seating quality inspection under backlight before the labeler

Layout for creams, masks, and lotions of higher viscosity in a jar with a screw cap.

1Empty jar feeding (unscrambler)
2Container purge before filling
3Piston doser with product heating
4Cap fitting and screwing
5Fill level inspector
6Labeling machine
7Date coding and batch marking
8Case packing with dividers

Key line stations

What sits behind the nameplate output: contact-part execution, operating logic and service points for every station.

Rinsing heads

Container preparation

AISI 304/316 stainless nozzles and manifold with fan-jet spray: lower water consumption and more even rinsing over the entire inner surface.
Neck-grip gripper with a polymer insert holds the bottle by the finish, minimizing the risk of preform crushing or scratching.
Rinsing pump and piping in sanitary design, the circuit disassembles without tools.
Rinse-water recirculation with filtration — up to 30% savings compared to drain discharge.

This station's equipment in the catalog

Core machines of the line

Equipment of the “Cosmetics Filling Line” layout: each tile opens the catalog with series, specifications and a quote request for that machine.

Bottle feeding and orientation

The unscrambler places bottles or jars on the conveyor in the correct orientation; a counter synchronizes feed rate with the doser.

Piston doser for creams and lotions

Contact volumetric piston dosing with a heated product tank and dip nozzle — no foaming on high-viscosity emulsions.

Filling block for liquid products

Diaphragm or piston pump for shampoo, shower gel, and liquid soap with fill-speed segmentation by viscosity.

Quick-change format parts

Neck grippers, starwheels, and guide rails change without tools — switching between jar, tube, and bottle takes minutes.

Capping machine with pump doser

Fitting and crimping a pump, dispenser, or flip-top cap with seating force monitoring on the neck.

Fill level and appearance inspector

Backlight inspection of the container: fill volume, foreign inclusions, and cap seating quality.

Labeling machine

Self-adhesive label on round or flat containers, with a back label on jars and tubes if required.

Date coder and batch marking

Printing batch number, manufacturing date, and shelf life on the bottom or shoulder of the bottle.

Case packing and palletizing

Placement into corrugated cases with cardboard dividers for small containers, sealing, and pallet formation.

Which closure do you use

The cap type defines the capping block: heads, feeding and orientation of the closure, torque or press-on force. State your option in the request and we will select the head and sorter for it.

24/410, 28/410

Dispensing pump / trigger sprayer

The dip tube is cut to the bottle height, the head screws it on without the tube twisting inside the container.

Capping unit: Capping head with oriented pump feed

24 mm, 28 mm

Flip-top / disc-top cap

The closed cap is fed pre-oriented to the label so the flap faces the right direction after capping.

Capping unit: Press head + tightening

PCO 1881 / 28 mm / 38 mm

Plastic screw cap

The tamper-evident band tears on opening. Torque is set on the HMI and monitored on every chuck.

Capping unit: Magnetic screwing head

Capping machines in the catalog Match a capper to my container

Auxiliary systems of the line

The engineering utilities without which a line never reaches its rated output: water and product preparation, sanitation, container handling.

Water treatment

Purified water for cosmetic formulations.

The scheme is built from a feed-water analysis: mechanical filtration, carbon, softening, reverse osmosis
Station output sized with a 20% margin over peak line consumption and wash cycles
Membranes with automatic flushing and VFD-driven pumps — no water hammer
UV and ozone disinfection, AISI 316 buffer tank with a breather filter

Reactor area

Preparing cream, emulsion or gel.

Vacuum homogenizer with a heating/cooling jacket
Mass-based oil-phase and water-phase dosing, version-controlled recipes
Emulsion deaeration — a bubble-free product with a uniform texture
AISI 316L buffer vessels with sanitary fittings

Filling viscous products

Tubes, jars and bottles.

Piston dosing at ±0.5% accuracy with a lifting nozzle
Heated path for thick creams and wax-based formulas
Quick-change contact parts for frequent SKU changeover
Small batches from a few hundred units without product loss

Capping and tube sealing

Finishing the cosmetic package.

Tube orientation by mark and hot tail sealing with batch embossing
Pump, dispenser or flip-top fitting with torque control
Induction membrane for first-opening protection
Cap presence and seating inspection with rejection

CIP station (clean-in-place)

Wash of the emulsion path after every formulation.

Alkali, acid and hot-water tanks holding temperature within ±2 °C
Recipe-driven wash programs: phase time, concentration and flow are logged
Flow meter on the supply line — actual flow is verified, not assumed from the nameplate
Filtered detergent return to the tanks; discharge only once the solution is spent

Coding and inspection

Batch, date and PAO marking on the pack.

Inkjet or laser coder: date, shift, batch number, traceability code
Fill-level, cap presence and seating inspection with automatic reject to a pocket
Good/reject product counters logged per shift hour
Ready for mandatory marking: case and pallet aggregation at the line outfeed

Packing and palletizing

Individual carton, case and pallet.

Shrink film pack or corrugated case, format tailored to the retailer's requirements
Layer palletizer to a defined pattern, robotic version for constrained floor space
Pallet wrapper with pre-stretch film: lower film consumption, pallet withstands transport
SSCC pallet label printing and application, data handoff to the ERP system

FAQ

How accurate will a 30 ml cream fill be?

The servo-piston doser gives a deviation within ±0.5 % of the dose, i.e. about ±0.15 ml on 30 ml. A checkweigher keeps this value stable throughout the shift.

Is the line suitable for pharmaceuticals?

Yes, in a version with a clean zone, validatable washing and documented batch traceability.

How much does the Cosmetics Filling Line cost?

Price on request: the budget depends on output, container type, line composition and the level of automation. After a short brief we send a preliminary estimate within 1–2 working days and a full quotation broken down by machine within 3–5 days.

What are the delivery and commissioning lead times?

Standard machines ship 8–12 weeks after the specification is confirmed, complete lines 12–20 weeks. Transport takes 2–6 weeks depending on the route; installation and commissioning on site take 2–4 weeks, with operator training included.

What output does this line reach?

The working range is 800–6,000 units/h. Exact output is confirmed against your container, product and shift plan: we calculate the line balance and keep a margin on the bottleneck machine.

Request a quote: Cosmetics Filling Line

Tell us the product, the container and the target output — we will return the line composition, a layout, a budget range and a delivery schedule.

Services for this line

Engineering, logistics, installation and service that turn this line into a working production site.

Engineering services

Business plan and financial model for a bottling line

We calculate project payback before the contract is signed: scenarios for raw materials, currency, sales channels and line load. The output is a document you can take to a bank, an investor or the board.

Technical audit of the site and production facility

Our engineers visit the site and survey the workshop, utilities and logistics. We record site constraints before they turn into rework during installation.

Financing, leasing and subsidies

We prepare the document package for banks and leasing companies and help you access agricultural and regional support programs. Typical savings: 8–14% off the rate.

Site selection and construction works

We help choose a plot or existing building, connect utilities, prepare the master plan and manage construction — from groundbreaking to workshop handover.

Process line design

Technology, specification, layout, throughput and utility calculations. The document equipment is ordered against and installation is carried out with.

Equipment supply and logistics

Contracts, customs clearance, insurance, multimodal delivery "to the workshop door" anywhere in the world — CIS, Europe, MENA, Asia.

Digital layer

Any line can be supplied with a digital layer

SCADA, MES, OEE monitoring, batch traceability and integration with plant systems — engineered together with the line, not bolted on later.

Production digitalization How we work: customer portal