Cosmetic Filling & Assembly Automation

The brief. In cosmetics, quality, accuracy, efficiency and cost all decide whether a product succeeds — and presentation is part of the product. A cosmetics manufacturer was filling and finishing largely by hand: fill weights drifted, changeovers between product variants were slow, and inconsistent capping and labelling risked the flawless finish the brand is sold on. They needed to lift throughput and consistency without compromising a premium look.

What we did. Automation Republic designed, built and commissioned a coordinated filling and assembly line. Servo-driven filling heads meter each dose to a precise, repeatable weight — cutting giveaway and rework — while AFAG handling and feed modules present bottles, jars, pumps and caps gently and consistently. Capping is torque-controlled for a secure, even seal, and monitored assembly steps verify that every unit is complete and correctly presented. A recipe-driven touchscreen HMI stores each product's parameters, so switching variants or pack sizes is a screen selection rather than a mechanical strip-down. The line was built in our in-house panel shop to a clean, hygienic standard and handed over fully documented.

The platform. We built on B&R — ACOPOS servo drives and X20 I/O over POWERLINK deliver the precise, tightly coordinated motion that accurate filling and delicate handling demand, engineered in one Automation Studio environment. The recipe model turns product variety into a strength rather than a bottleneck. As with every AR line, we're vendor-flexible: the same solution can be delivered on Siemens, Rockwell/Allen-Bradley or Mitsubishi to suit your standard.

The result. Fills are accurate and consistent, changeovers are fast, and every unit comes off the line with the finish the brand demands — throughput up, giveaway down, and quality no longer riding on manual care. The customer owns clean documentation and code, with VPN remote support on hand to tune and update the line as the product range grows.

Filling and finishing cosmetics by hand? Let's build a line that's precise, quick to change over and true to your brand.