WILPAC Cosmetic & Personal Care Packaging Lines: Vacuum De-aerated Filling for Creams, Lotions and Serums

Cosmetics and personal care products combine two packaging challenges that rarely appear together: very small fill volumes, often measured in millilitres, and formulations that are sensitive to air, shear and contamination. WILPAC has built a dedicated cosmetic packaging line that addresses both, covering filling, plugging, capping, sealing, coding and cartoning in one controlled flow suitable for creams, lotions, gels, serums and cleansing products.

At the centre of the line is a vacuum de-aerated filling system. Product is held under controlled vacuum so that entrained air is drawn out before dosing, which eliminates the bubbles and surface foam that otherwise create short fills and reject bottles. Dosing is performed by servo-driven piston or peristaltic pumps, selected according to the viscosity of the formulation, and accuracy is held to plus or minus 0.5 percent on fills as small as 15 millilitres. Hardened stainless nozzles are profiled to enter narrow necks and to cut off cleanly, so no product smears across the thread or the sealing lip.

Because cosmetic packaging takes many forms, the line is deliberately modular. One configuration handles airless pump bottles, where the piston platform is pressed upward without exposing the formula to air, extending shelf life for actives such as vitamin C and retinol. A second handles cosmetic tubes, filling, folding and sealing the crimp at the base before the cap is tightened. A third fills glass or PET dropper bottles for serums and essential oils, inserting the glass pipette and applying the collar to a defined torque. All versions share the same filling platform and can be changed between formats with recipe-driven parameter recall.

Hygiene is treated as a design requirement rather than an accessory. Product-contact parts are stainless steel 316L, shafts run in sealed bearings, and the filling head can be specified with CIP and SIP capability. The machine frame is built to be wiped down and drained, with no open crevices where residue could accumulate, in line with cosmetic GMP expectations. Downstream, the line applies tamper-evident induction seals or shrink bands, prints batch and expiry codes by inkjet or laser, and completes shrink-wrapping or robotic cartoning. For brands selling across the EU, North America and the Middle East, the system supports the batch traceability and labelling requirements that each market enforces.