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In the past two years, OPI has invested heavily in new packaging technologies to adapt to exponential growth and installed five new production lines.
One of the new changes was the installation of Capmatic's IntrepidTM FC42 monomer filler/capper for packaging one ounce of lotion product. This line is designed for the introduction of a unique filling system for lightweight plastic containers that is compatible with the Capmatic LabelStar 2/2 front and rear labeling machines. Another new machine installed by the company is Norden's NM700 hose filling machine, which solves the dilemma that OPI faces with the need to develop nail polish products.
One million dollars a year
Today, the United States and 100 countries around the world are selling OPI's fashion nail oil (containing natural silk amino acids and precious pearl powder, with a porcelain-like color) and related products. The company also launched a nail polish line, Nicole, to the retail market while supplying products to professional salons and beauty product distributors.
Since Schaeffer entered the nail industry, OPI has expanded from a two-bedroom office to a 20-story 20-square-meter building that occupies 7.5 acres in North Hollywood. At present, the scale of OPI is still continuously expanding. Allen said that despite the economic downturn in the United States, OPI sales will increase by more than 30% this fiscal year. We have also encountered the economic downturn before, but the cosmetics industry is not affected. According to his speculation, the company’s international sales now account for almost 40% of the entire business, which is another success for the company.
He added that to cope with this growth trend, OPl spends at least one million dollars each year investing in packaging equipment, including equipment upgrades, equipment maintenance and the purchase of new equipment.
Filling system ensures that the bottles are neat
In January 2007, OPI installed the FC42 filler/capper to increase production of the AvojUiceSkinQUenChers body cream line and AvOPIex brand hand cream. Avojuic skin cream is packaged in oval-shaped or conical PET bottles with an ounce capacity. There are six types of fragrances, two kinds of promotional items, and a special seasonal fragrance. There are three types of AvoPlex brand hand creams, all in one ounce. The style of the bottle is the same as that of Avojuic; the difference is that its bottles are made of high-density polyethylene. TricorBraun supplies bottles for packaging, and Seaquist Closures supplies its spring-loaded caps. AvePlex Exfoliating Scrub uses one-ounce, compact, low-density polyethylene bottles from TriCOrBraun. AIico Packaging offers caps and stoppers for this product.
During the interview with the OPI factory, the company is working hard to produce one ounce of Tropical Lemon Massage Cream for promotional activities. According to AIlen, OPI uses the FC42 filler/capper every year to produce nearly seven million bottles and one ounce of product, and is equipped with corresponding featured products to promote sales. Allen also said that FC42 has the advantages of high accuracy, high reliability and good flexibility. He also praised the supplier of the equipment: Cap-matic company is a leader in customer service, flexibility, and performance of machinery and equipment.
He went on to say that with the help of the various IntrePid packaging lines already installed, the company solved the problems encountered in the production speed and special packaging components. In the case of IntrepidTM FC42, Capmatic must specifically design a system to produce those ounces of detergent bottles. Bottles cannot stand on conveyor belts until they are full, so we used to have to straighten each bottle and send it directly to the knife or index wheel before filling. The first step in the operation of this filling system is for the staff to operate bulk hoppers and those ounce-sized bottles. As a result, the bulk feeder lifts the bottle up and is placed on the Capmatic automatic stacker. The bottles are directed to a horizontal conveyor and then divided into two chutes. The bottle follows the chute toward a single filler/capper. Fill two bottles in the index wheel each time before filling. This step involves a lot of engineering things. This system is doing great.
Up to 95% efficiency
In the filling phase, two bottles are placed at once and the bottles are capped. Intrepid itself is equipped with Rockwell Automation's Allen-Bradley PLC and Festo's gas installation. It has an excellent local design and the filling process is divided into two stages: the first stage fills the bottle with half a bottle, and the second stage continues. AIlen explained that OPI's engineers modified the equipment and dismantled the preparatory phase so that filling became a bottom-up single process. The production rate is thus increased, from 80 bottles per minute to 90 per minute, with an efficiency of 95%. One operation of the equipment can fill more than 30,000 bottles.
The Capmatic funnels use bulk feed elevators to carry the caps into a bowl. As long as there is a worker, the capping operation can be performed through the funnel.
After the bottle is withdrawn from the single filling machine, it reaches the star wheel via the conveyor belt. At the bottom is the A200 small-format inkjet printer from Domino Amiet. The upper bottle will be bar coded at the bottom. Capmatic's LabelStarSystem 2/2 labelling machine labels the bottle front and back at the same time. Subsequently, the stepper motor simultaneously operates two types of label heads and a belt of a synchropressor.
The labelled bottles reach the polymerization after leaving the conveyor belt, and two workers pack and load the trays. In addition, a third staff member is required to monitor the entire production line.
Hose fillers cater to growing demand
OPI increases the production capacity of hose filling machines against booming manicure production lines. Six years ago, the management realized that the SPA salon was about to become popular all over the world, so it entered the manicure market. Today, its foot protection products can generate sales of $6 million to $7 million a year.
OPI installed a Norden 700 hose filling machine in March. Before installation, it had to use the Norden NM602 hose filler. Allen recalled: At the time I had to hurry to buy a new machine, so it took only 90 days to bring the new machine from Sweden, and the speed was so unprecedented. This new machine is also equipped with custom-made application software! It works beautifully.
Allen said that it chose the NM700 because Norden hose filling machines are the best in the industry.
This line is mainly for the OPI filling 4.2 ounces and 8 and ounces of products, also involving 1 ounce of grease products, 17 ounces and 42 ounces of detergent products. Coextruded hoses were initially purchased overseas and later supplied seals and caps to OPI. OPI added a hose extrusion operation to test the closure force of the filling package. The hose is sent to a pinching system via a conveyor to ensure complete closure.
Easy to operate and reduce manpower
While the NM700 is in operation, the worker places the hose horizontally on the refilled platform and can fill nearly 90 bottles. Each hose is placed in a dump, where the hose is treated separately and side-capped and pushed into the pending disc. The detector identifies the identification code on each hose and then properly fills and caps it.
In the next stage, after the hose is lifted, the piston filling machine fills it. Once filling is complete, the hose is indexed in the seal/folder, the open end is sealed, and the hose is integrated. The filling machine is integrated by the individual controllers and the PLC produced by Elau.
The hose passes through the sealing inspection device and the sealing device stage, after which the staff then loads the hose into the carton or tray.
Allen said: The NM700 is very simple to operate.
AIlen believes that good cooperation between OPI and equipment suppliers is a major factor in the successful installation of new equipment. He said: Even for big projects, our company can easily negotiate with suppliers. Words are more important than any paper contract. We respect each other.
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