A tailored filling solution from Greif-Velox enables higher throughput, consistent quality, and greater flexibility for cosmetic ingredient production
Symrise AG has fundamentally modernized the filling of cosmetic ingredients at its production site in Goose Creek, South Carolina. The aim was to automate physically demanding processes, increase plant performance, and ensure a high degree of flexibility when handling different viscosities and container types. In collaboration with packaging machinery manufacturer Greif-Velox from Germany, a customized, fully automated filling solution was implemented—with measurable success.
Initial Situation: Limited Performance and High Physical Strain
Before the project began, Symrise operated a semi-automatic filling system for canisters at its Goose Creek facility. Two employees working in shifts manually lifted 25-kg canisters onto a roller conveyor, initiated the filling process, sealed the containers, labelled them, palletized them, and prepared them for further transport. In addition to the considerable physical strain, the process quality was limited. Variations in filling volumes and closures led to complaints, and the daily output of around 6,000 kg was no longer sufficient to meet increasing production volumes and the introduction of new product variants.
Greater Flexibility and Quality Through Automation
The project aimed to address several key challenges:
- Increasing filling output while maintaining consistent quality
- Reducing physical strain and personnel requirements on the line
- Enabling flexibility for different container types (canisters, drums, IBCs) and product viscosities (77–4,254 mPas)
- Improving process reliability and quality assurance
- Preparing the system for future requirements, including ATEX compliance
Technical Solution: Fully Automated Filling Lines A-DOS-K and A-DOS-P1
The solution provided by Greif-Velox consists of two highly automated filling systems: the A-DOS-K for canisters and the A-DOS-P1 for drums and IBCs. The A-DOS-K is equipped with two filling lances, enabling parallel filling—an important factor in increasing throughput. The system is complemented by conveyor technology, robotic palletizing, labelling, and strapping. A key feature is the fully integrated automation of the entire process. From destacking empty containers through filling, closing, and labelling to robot-assisted palletizing and load securing, every step is carried out automatically.
One special feature developed specifically for Symrise is the automated removal of dust caps from the canisters. This previously manual process was not only time-consuming but also prone to errors and hygiene risks—particularly when canisters without caps entered the filling process, making potential internal contamination impossible to rule out.
In the new system, the canisters are opened fully automatically. Containers in which the cap is already missing or cannot be reliably removed are detected and consistently removed from the process.
Increased Productivity and Process Quality
The transition to a fully automated filling solution has led to a significant increase in productivity at Symrise. Previously, around 240 canisters were filled per day; the new system now achieves a capacity of up to 130 canisters per hour—representing a performance increase of more than 330 percent.
“A major advantage of the new system is the complete relief it provides for our employees when handling the heavy 25-kilogram canisters,” says Maik Ulbig from the Process Optimization & Engineering department at Symrise. “Manual movement is eliminated entirely, as all lifting, sorting, sealing, and palletizing operations are automated.”
This allows resources to be used more efficiently, as freed capacities can be deployed elsewhere in the production process.
“In addition, the containers are precisely positioned, reliably strapped, and closed with consistent torque. Labelling is also carried out with continuous precision and repeatability,” Ulbig explains. “This results in a clean overall appearance and a high level of customer satisfaction.”
Process reliability has also improved significantly. All filling quantities and closure torques are documented and monitored, ensuring consistently high quality and complete traceability. The new systems also offer a high level of flexibility, processing different container types—from canisters to drums and IBCs—and products with widely varying viscosities with only minimal changeover times.
Standardization of Processes
Automated labelling, strapping, and robotic palletizing create neatly structured and uniformly filled pallets that not only present a high visual quality but also ensure reliable load securing. In addition to increased customer satisfaction, this establishes consistent standards in internal logistics and shipping. With the new filling solution, Symrise has not only significantly increased production performance at its Goose Creek site but has also improved employee ergonomics and sustainably enhanced the quality and traceability of its processes.