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Toothpaste filling Equipment

Filling lines are used extensively in all industries, such as food, pharmaceutical, chemical, and cosmetics, to accurately package different products into a container suitable for that product. Although the filling process is at the very end of the production line, it is no less important than the earlier steps. Last but not least, the idiom that dates back to 1382 when John Wyclif wrote the firste the laste, and the laste the firste, indicates just that the last things on a list are just as valuable as the previous ones. In this case, this idiom fits perfectly.

Filling

It's been estimated that we spend an average of 3,000 hours brushing our teeth. In fact, in our daily routine, toothpaste is something we use at least twice a day. Making toothpaste is a very straightforward process; just mix together water, abrasives, humectants, thickening and foaming agents, sweeteners, and flavors in the right amounts until you get a paste. Once you have added the colors, you can fill a tube with your colorful toothpaste and seal it before being shipped to stores.

Toothpaste

Filling and capping bottles and pots for food, chemical and cosmetics industries using separate machines is expensive and inefficient.A better solution is a combined monoblock unit, that will save space and cost, whilst increasing product throughput, even on multi-product lines.
<h3>Monoblock combined filling and sealing machine</h3>
EFM Monoblock filling machine is an easy-to-use, multi-purpose machine designed for filling and capping of containers with lids or pressure caps. Featuring a touchscreen system, the machine is easy to operate and allows simple readout and storage of all function information.

EFM’s design philosophy is to provide adaptable machines suitable for a range of industries. The Monoblock filling machine can be used with a wide variety of filling methods, including digital flow metering, piston pumps, peristaltic pumps, and more.

For the sealing process, a choice of methods is available including manual positioning of lids, or use of a fully automated cap supply system that uses pick and place. Final tightening can be by magnetic capping, servo capping, pressure capping or pilfer proof capping, to suit your requirements.

Compact monoblock filler

For larger production runs of food, non-food and cosmetics industries, where accuracy and volume of filling is required, a fully-automated vessel filling solution that works seamlessly with your line is vital. Ease of operation and precision control over fill volume of a large spectrum of liquids provides maximum flexibility for multi-product environments.


<h3>Flexible high-volume flowmeter solution</h3>
The EFM F-Series is a fully customisable, high accuracy, high volume filling machine. Capable of operating with a wide spectrum of liquids, the F-Series is available in 2,4,6, or 8 head versions. The high efficiency supply pump transfers product directly to the flow meter, where it’s then sent in compressed tubes to the fill valves, which are servo-controlled for accuracy of placement.

Fitted with electromagnetic flow meters by default, the EFM F-Series can also be supplied with mass flow meters for use with non-water-based product. It can also be fitted with conductivity measurement where required.

The F-Series is made primarily of stainless steel, and it’s designed to be easily and quickly disassembled for cleaning.

Flowmeter filler

For food and non-food liquid products that are high foam or have a high viscosity a specialist filling solution is required. Whether filling jars, cans, bottles, top-downs or bowls, the filling machine needs to offer high levels of accuracy and reliability whilst being able to operate at high volumes.


<h2>Servo-controlled piston filling machine for high viscosity liquids</h2>
The EFM Servo Piston range of filling machines has been designed specifically for use with high viscosity and high foam liquids in the food, chemical and cosmetics sectors. Featuring robust all-stainless construction and high quality Siemens PLC and touchscreen control, the Servo Piston variants offer accurate and reliable fills at up to 5,200 bottle per hour.

Featuring standardised components for ease of maintenance and minimal downtime, the EFM servo piston machines are designed to handle volume ranges from 15cc up to 1,100cc depending on configuration.

For speciality products there are a wide range of options and upgrades available, including heated product tank, product agitators and nitrogen injection.

Constructed in the Netherlands, EFM also offers an optional remote support service for complete peace of mind.

Servo controlled filler

For the stand-alone capping of bottles of up to 30 litre capacity for smaller-scale production you need a robust and flexible machine with high accuracy. Used in the beverage and chemicals industries, bottle cappers need to be reliable and fast, and for maximum flexibility need to be able to deal with a range of caps.


<h2>Flexible single-head capping machine for smaller-scale production lines</h2>
The EFM range of single head capping machines offer maximum flexibility together with impressive performance for smaller scale production lines. These all-stainless machines feature Siemens PLC and full touchscreen controls for accuracy and ease of use. The use of standardised components throughout from high-quality manufacturers increases longevity and reduces the downtime for any maintenance. The gravity-fed cap sorter and magnetic torque head provide high levels of reliability.

Able to handle a wide range of caps types, including screw caps, push ons, non-vacuum twist-offs and pilfer proof, the EFM single-head range includes a standard edition able to cap up to 2,200 bottles per hour, and a servo-controlled edition capable of up to 2,600 bottles per hour.

Featuring a star wheel positioner as standard, the machine is able to fill bottle of up to 2.5 litres. However, by specifying the option using gates larger packages from 5 up to 30 litres can be filled by this machine, providing great flexibility.

Other options include high torque sealing, torque verification and Detect and Reject system for full capping verification. The units are also available with an optional remote support package direct from the manufacturer.

Single head capper

A wide variety of pharmaceutical, cosmetic and food products require tube-style packaging. An automated tube-filler adds flexibility to production lines by not only filling, sealing and capping tubes with high levels of accuracy, but also offering additional features such as labelling and in-built quality checks.


<h2>Tube filler with additional flexible features</h2>
The TFS-15 from IWK is an automatic tube filling machine that operates in the lower speed range, and is suitable for moderate scale production lines. It features 10 workstations that can handle tubes from 10 to 60mm diameter and can accurately dose from between 1.5 ml and 400 ml of product at up to 90 tubes per minute. High-precision dosing is guaranteed by an infinitely variable, play-free direct pump drive.

The highly flexible TFS-15 allows for rapid changeover between tube and product types. Product-handling parts are changed out as one unit. Sizing parts can be simply and quickly changed out without the use of tools. These minimise downtime associated with product changes.

The TFS-15 also offers two-component filling and the ability to fill applicators, expanding the range of products it can be used with. Labelling can be achieved with laser or inkjet printing as well as embossing.

Designed to deliver constant high quality tube folding or sealing, the TFS-15 has inbuilt quality control checking that will detect and eject bad tube seals and incorrectly fitted or missing caps.

Suitable for use with a wide range of products, the TFS-15 can fill and close cylindrical (with EURO-hole, curved seal) oval or conical tubes, dispensers (including inserting of pistons), mascara brushes, cartouches, jars, and tottles (with capping).

A two-component filling application tube filler

Increasing numbers of products in the pharmaceutical, cosmetic and food industries are delivered in flexible tubes, bottles or dispensers. Automated tube filling machines improve production efficiency by accurately filling, sealing and capping a range of tube-based packaging with minimal operator intervention. For smaller-scale production environments, large filling machinery is impractical and expensive.


<h2>Automatic tube filler for small scale production</h2>
The FP-10 from IWK is a next-generation tube filling machine that operates at lower speeds, most suited for small scale production. It features 10 workstations that can handle tubes from 10 to 52mm diameter and can accurately dose from between 1.5 ml and 300 ml of product at up to 70 tubes per minute.

The FP-10 has been designed to allow for rapid product changeover, and all components can be switched out in a little as 15 minutes, keeping downtime to a minimum.

The FP-10 benefits from the latest servo technology, giving the machine extremely high reliability and minimum maintenance. A new 5.7” touch panel HMI not only displays all relevant process parameters, but also allows profile storage and data recording. Internet connectivity allows for remote diagnostics and servicing.

Able to fill metal or plastic containers, the FP-10 can perfectly contour seal plastics with hot air and offers double, triple or saddle folding for metal tubes to meet your exact requirements.

Suitable for use with a wide range of products, the FP-10 can fill and close cylindrical (with EURO-hole, curved seal) oval or conical tubes, dispensers (including inserting of pistons), mascara brushes, cartouches, jars, and tottles (with capping).

Low speed tube filler

For scale-up filling of tube packaging for pharmaceuticals, cosmetics and food products, a medium-speed automatic tube filler is required that meets increased demands of speed and volume with high levels of accuracy and minimum downtime. The ability to handle a wide variety of packaging types, and to cap and seal in different ways means additional flexibility that results in increased efficiency.


<h2>Scale-up tube filler for increased efficiency at higher volumes</h2>
The IWK FP Series is a latest-generation modular filling and sealing machine for tube-based containers. Designed with reliability, ease of use and performance as a priority, the FP Series uses the latest servo technology throughout to provide industry-leading levels of reliability.

The range features 18 to 64 workstations that can handle tubes from 10 to 63mm diameter and can accurately dose from between 1.5 ml and 700 ml of product at up to 300 tubes per minute.

The modular design of the FP Series allows it to be configured to your exact requirements, both in terms of operations and functions and floor layout. 5 servo drives (with an additional 4 as options) are at the heart of the oval transport system and offer high level of accuracy together with a robustness that keeps maintenance and downtime to a minimum.

The FP Series is available with a large range of options that means it can be tailored to your exact requirements. Options include tube feeding systems, in-line checkweighing, frequency welding, droplet dosing and many more.

Multi-colour tube filling is available and features the IWK patented swing-out quick change system for rapid changeover. Multi-colour fill types include sandwich, deep stripe, surface stripes and core striping.

The newly designed HMI features a 15” touchscreen control with graphical status reporting and diagnostics, and is fully 21CFR part 11 compliant for auditing and reporting.

Medium speed tube filler and sealer

When scaling up production of pharmaceutical, food or cosmetic products that use tube containers, increasing speed and throughput without compromising on accuracy and quality are vital. Tube fillers need to be able to handle a wide range of packaging types and allow for rapid changeover to benefit from their flexibility and speed.


<h2>Small footprint, GMP-design medium to high speed tube filler</h2>
The IWK TFS-E Series benefits from a range of innovations that result in a robust, easy-to-use and maintenance-free tube filling solution for medium scale production.

The TFS-E Series features 20 workstations that can handle tubes from 11 to 52mm diameter and can accurately dose from between 1 ml and 350 ml of product at up to 220 tubes per minute.

Designed with flexibility in mind, the TFS-E features a format change over time of less than 25 minutes, and storing and recalling all relevant process parameters to guarantee a vertical start up. All product-contacting parts are swapped out “en bloc” which gives the maximum efficiency whilst allowing for a range of product. The patented IWK dosing system is supremely accurate but also simple to maintain, thanks to Clean in Place in under 5 minutes.

Able to fill metal or plastic containers, the TFS-E Series can accurately contour seal plastics, and offer a choice of double, triple or saddle folding for metal tubes to meet your needs.

Suitable for use with a wide range of products, the TFS-E Series can fill and close cylindrical (with EURO-hole, curved seal) oval or conical tubes, dispensers (including inserting of pistons), mascara brushes, cartouches, jars, and tottles (with capping).

A wide range of options enables the TFS-E Series to be specified exactly to your requirements. Options include multi-colour filling, tube de-dusting, in-line checkweighing, automatic central lubrication system, and many more.

Medium and high speed range automatic tube filler

For high-volume lines filling pharmaceutical, cosmetic or food products into tube containers, high speed and throughput must not come at the compromise of fill accuracy and sealing quality. High performance tube filling machines successfully match performance with quality, using a range of technological advances to ensure the maximum efficiency and rapid ROI.


<h2>World’s fastest high efficiency tube filler with advanced features</h2>
The TFS-80 Series from IWK is a high-performance, next-generation tube filling machine that is most suited for large scale production environments. It features up to 24  workstations that can handle tubes from 22 to 40mm in diameter and can accurately dose from between 2 ml and 220 ml of product at up to 750 tubes per minute.

The TFS-80 Series is officially the world's fastest tube filler, and yet it’s new weight checking and quality control system guarantees accuracy, reducing tube overfilling significantly. By using a clever modular design, workstations can be retrofitted with ease for maximum flexibility and future expansion, making development of new packaging or product types simple.

Because it operates with such high performance, the TFS-80 Series has been engineered for reliability and efficiency. Many traditional mechanical actions have been rendered obsolete by the use of servo technology throughout. State of the art bearings with central lubrication system allow for long service intervals, reducing maintenance costs. 

For greatly reduced downtime caused by product changes, fast exchange systems are employed. New motion parameters are automatically set via servo drives in case of product changes. The touch screen panel HMI makes these operations quick and easy, as well as allowing simple monitoring of the machine in use. Internet access allows remote diagnostics, further reducing any downtime.

Despite the high performance of the TFS-80 Series, it’s been designed to occupy as compact a form-factor as possible, providing maximum flexibility when it comes to your own installation.

High speed automatic tube filler

High performance tube-filling machines are used in the pharmaceutical and cosmetic industries. Their performance is greatly enhanced by the use of automated feed-in systems, delivery the empty tubes accurately and quickly to maximise the efficiency of the filler. Loading systems are available in a variety of formats, including the flexible cassette type.


<h2>Feed cylindrical tubes via a cassette</h2>
Ensuring a constant supply of appropriately orientated empty tubes, the IWK TZM Cassette Tube Feeding Magazine is suitable to supply machines operating at up to 120 tubes per minute.

The TZM allows for uninterrupted operation because it holds tubes in a reservoir between the tube filler and tube feeding magazine. Tubes in the reservoir are processed first, meaning restocking the filler will not impact on the operation. A photo-electric backup sensor monitors

the tubes in the reservoir ensuring it does not run empty.

The TZM aligns tubes into singles by using pneumatic baffle plate movements in the magazine and the reservoir area. Individual tubes are picked up at the far end of the tube filler chute and loaded in the tube filling machine.

Suitable for use with laminar flow, the TZM gently handles tubes, minimising damage to fragile materials. The TZM is able to handle all commercially available tube materials, and operates with tubes of diameter 13.5 mm to 40 mm, and length 60 mm to 230 mm.

Size changeovers are very quick to minimise downtime and don’t require the use of any tools.

Loading cassette for a tube filler

In the pharmaceutical, cosmetic, and food industries, achieving precise and efficient filling and closing of various types of tubes is crucial. Challenges such as maintaining product quality, ensuring accuracy, and minimizing waste necessitate advanced, reliable solutions.
<h2>Fills and closes tubes accurately and efficiently</h2>
The AXO 2600 by Axomatic, part of the Marchesini Group, is an advanced filling and closing system designed for metal, laminated, and plastic tubes. This stainless steel AISI 304L system features a touch screen control panel with Industry 4.0 compatibility, ensuring easy operation and data management. The ergonomic tube loader accommodates large capacities, while an electronic sensor regulates the no-tube no-filling control. Accurate tube orientation is facilitated by a registration mark scanner, and dosing operations are managed by two independent dosing groups with servomotor drives. The system includes a new hot air sealing mechanism with low air consumption and customizable sealing options. This machine is characterized by its easy-to-clean components, 26 turntable stations, and comprehensive CFR 21 PART 11 and Full Atex certification options. It is suitable for filling products in various industries, including pharmaceuticals, cosmetics, and food.

Automatic tube filling and closing system

Producing high-quality lotions, creams, and gels requires specialized equipment due to the complexity of mixing and homogenizing high-viscosity products. This ensures uniform texture and optimal product quality, which traditional methods often fail to achieve efficiently.
<h2>Homogenize and mix with precision and speed</h2>
The EKATO UNIMIX vacuum processing units offer a versatile solution for producing various high-viscosity products such as lotions, creams, gels, and toothpastes. Combining the patented EKATO PARAVISC impeller and the EKATO S-JET homogenizer, these units ensure rapid, effective mixing and homogenization. The PARAVISC impeller provides excellent axial mixing, while its open design allows for the use of a central baffle and wall scrapers, optimizing heat transfer. The S-JET homogenizer is designed for internal and external homogenization, enabling swift and precise product dispersion. The system supports capacities ranging from 100 liters to 20,000 liters and includes features like heating and cooling functions, automated feeding, and Cleaning in Place (CIP) systems. It meets ASME, PED, and SELO standards, ensuring reliable performance across industries such as cosmetics and pharmaceuticals.

Vacuum processing units for high-viscosity products

ProXES specializes in liquid and semi-liquid foods, cosmetics, and pharmaceuticals process machines and lines. ProXES partners from co-creating first ideas,developping tailor-made concepts, go to market and scaling production.

Ever found yourself squeezing on a visibly empty toothpaste tube, hoping to extract every last bit on your toothbrush? So have we. While this daily ritual might go unnoticed, there is true magic behind the tube.



Now is your chance to find out more! ProXES is hosting a free webinar called “Discovering and solving the challenges of toothpaste production”. For all of us to learn more about an otherwise normal detail of our everyday routine.

Mark your calendar for the 28th of November and turn on your computer to attend the event online either at 9 AM or 4 PM (CET). <a href="https://go.proxes.com/en/webinar-toothpaste-production">Register</a> to secure a spot and be prepared to learn more about innovative technologies!

The event is hosted by Marc Cöslin, ProXES Non-Food Application Specialist, and Martin Koch ProXES Head of ProTec. With combined expertise of over 20 years, these two professionals are not only experts in processing technology but also excellent speakers, making even the most complex subjects easy to grasp.

Don’t miss out!

Webinar: unveil the secrets of toothpaste production

Cosmetic

According to a legend, Cleopatra soaked her sails in her perfume so that Mark Antony could smell her ships before they arrived. This is to say that, from soaps and shampoos to perfumes, conditioners and pomades, cosmetics have always been highly valued and used for their properties of aesthetic enhancement. Cosmetics are a broad class of topical agents applied for various purposes such as cleansing, protecting, beautifying, or otherwise altering your appearance. As a result, a wide array of processing equipment is used in the cosmetics industry.

Cosmetics

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