Cosmetic cream filling involves more than simple liquid dosing. Different textures, viscosities, and packaging formats often require customized filling structures and production configurations. From standard facial creams and body butters to swirl creams, gel capsule creams, eye creams, and hand creams, maintaining product appearance and dosing stability is critical. ZONESUN specializes in providing solutions that minimize air gaps, preserve texture, and ensure smooth handling across multi-SKU cosmetic products, with flexible filling, capping, and labeling options for jars, tubes, and airless bottles.
Cosmetic Cream Packaging Process
Cosmetic creams come in various packaging—glass jars, airless bottles, and squeezable tubes are among the most common. The packaging process for jars and bottles generally includes several steps: unscrambling, rinsing, filling, capping, labeling, and cartoning(as shown in the figure above). Tubes, however, require a different workflow: loading, filling, sealing, and cartoning. Cream viscosity typically ranges from 100 cP to 10,000 cP. This wide range means that manufacturers usually need customized filling systems—what works for a low-viscosity product won't necessarily work for a high-viscosity one. In both cases, the goal is consistent filling accuracy, smooth product flow, and clean, reliable packaging.
Main Cosmetic Cream Types
Standard Cream
Facial cream, moisturizing cream, body butter, balm, and other high-viscosity cosmetic cream products commonly packaged in cosmetic jars, acrylic jars, PET jars, or airless bottles. Hand cream and eye cream are also widely packaged in soft tubes or laminated tubes for controlled dispensing and portable use.
Swirl Cosmetic Cream
Swirl face cream, layered cream, multi-color cosmetic cream, and decorative skincare products typically packaged in transparent jars or clear cosmetic containers to display visible spiral or layered filling appearance after packaging.
Gel Capsule Cream
Capsule-in-cream skincare, suspended bead cream, and decorative cosmetic formulations containing visible gel capsules or essence beads, commonly packaged in transparent jars or airless containers to maintain decorative visual effect and product stability.
Main Cosmetic Cream Filling Challenges & Solutions
Air Gaps in High-Viscosity Cream
Challenge:
High-viscosity creams can trap air during filling, especially in wide-mouth jars or at higher production speeds.
This may cause uneven surfaces, internal voids, or inconsistent dosing.
Solution:
Servo-driven piston filling with lifting nozzles is commonly used to improve bottom-up filling stability and reduce air entrapment during dosing. In some applications, vacuum defoaming or material degassing before filling can also help reduce trapped air inside high-viscosity cosmetic cream products.
Swirl Pattern Stability
Challenge:
Swirl and multi-color creams require precise layering to maintain decorative patterns.
Improper nozzle or flow control can distort swirl shapes or create uneven spiral thickness.
Solution:
Multi-channel synchronized filling systems with dedicated swirl nozzles.
Controlled flow ensures stable spiral formation and consistent decorative appearance.
Gel Capsule Protection & Distribution
Challenge:
Suspended capsules or beads may sink, aggregate, or become unevenly distributed during filling.
Inconsistent capsule placement can affect the final decorative appearance inside transparent cream products.
Solution:
Two-stage filling structure with transparent base filling and separate capsule dosing.
Vertical nozzle movement helps place capsules more evenly inside the container and improves visual consistency after filling.
Cleaning & Product Changeover
Challenge:
Switching between different colors, fragrances, or oily formulations increases cleaning frequency and production downtime.
Residual cream inside pipelines and hoppers may affect the next production batch.
Solution:
Filling systems can be designed with CIP connection ports for integration with the customer's existing CIP system.
One-button cleaning functions can continuously circulate cleaning liquid through pipelines while discharging remaining material inside the filling system.
Multi-Format Packaging Compatibility
Challenge:
One line may need to handle jars, tubes, or airless containers with different diameters, heights, or caps.
High- and low-viscosity products may require different filling approaches.
Solution:
Adjustable handling structures and interchangeable components for different container sizes.
Dual or interchangeable filling systems to support both high- and low-viscosity creams.
Production Integration & Material Compatibility
Challenge:
Cosmetic cream manufacturers often need new filling equipment to integrate with existing labeling machines, capping machines, conveyors, and other packaging systems. Different cream formulations may also require heating, mixing, agitation, or homogenization before filling, while hygienic standards and material requirements can vary between products.
Solution:
Filling systems can be customized for seamless integration with existing production lines. Optional heating, mixing, emulsifying, and agitation functions help maintain product consistency during filling. Product-contact parts can be manufactured in AISI304 or AISI316 stainless steel to meet different cosmetic production requirements.
Case Study of Cosmetic Cream Filling Machine
A cosmetic manufacturer in Lithuania specializing in cream and shampoo production required a flexible filling and packaging solution capable of handling multiple container formats on a single production line.
The products included 30g cream jars (Ø47 × H36 mm) and 50g cream jars (Ø56 × H43 mm), both equipped with inner stoppers, as well as 80ml shampoo bottles (Ø36 × H126 mm) and 150ml shampoo bottles (Ø45 × H156 mm) fitted with 24/410 disc top caps.
The customer required stable production at 20–30 BPM with ±1% filling accuracy across both product types. Since the line needed to process both high-viscosity cosmetic creams and low-viscosity shampoos, it also had to support flexible container changeovers, reliable cap feeding for different closure formats, and reduced cleaning downtime between production runs.
Related Video of Cosmetic Cream Filling Machine
FAQ of ZONESUN Cosmetic Cream Filling Machine
1. Can the same machine fill both high-viscosity cream and low-viscosity cosmetic products?
In some applications, dual filling systems can be configured to support both high-viscosity creams and lower-viscosity cosmetic products on the same machine.
2. How can air gaps in cosmetic cream filling be reduced?
Servo piston filling with lifting nozzles is commonly used to improve bottom-up filling stability and reduce air entrapment. Vacuum defoaming or material degassing before filling can also help reduce trapped air inside high-viscosity cream products.
3.Can the ZONESUN machine connect with existing labeling or packaging equipment?
Yes. Conveyor layout, machine height, and transfer structures can be customized for integration with existing labeling machines, capping machines, conveyors, or other packaging equipment already used in production.
4.Does ZONESUN provide mixing tanks or raw material preparation equipment?
Optional mixing tanks, heating tanks, emulsifying mixers, storage tank, and agitation systems can be configured according to different cosmetic cream production requirements.
5.Can the machine be manufactured in SUS304 or SUS316 stainless steel?
Yes. Product-contact parts of ZONESUN filling machine can be manufactured in SUS304 or SUS316 stainless steel according to cosmetic formulation requirements and production conditions.
6.Is the filling system compatible with CIP cleaning?
ZONESUN filling system can be designed with CIP connection ports for integration with the customer’s existing CIP system. Some configurations also support one-button cleaning and continuous pipeline circulation cleaning.
Popular Blog
Просмотреть все
