Cosmetic Fill Line Sequencing for Flexible Container Verification
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Solution Overview
Problem
Conventional hair dye systems face challenges in efficiently producing and dispensing a wide variety of customizable hair dye formulations, lacking flexibility in packaging and optimization of the dispensing process, particularly when using large volume containers.
Innovation Solution
A system utilizing a conveyor belt, robotic arm, and vision sensor with embedded radiofrequency tags for container identification, combined with 'bag-in-box' components and intermediate bulk containers, enables flexible and efficient dispensing of multiple compounds into individual bottles, allowing for customizable formulations and optimized sequencing of bottles based on predicted fill times and AI-driven optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional system using large volume containers is used for producing hair dye formulations, then production efficiency is maintained, but flexibility in producing a wide variety of customizable formulations is limited
Solution Approach 1:
The system segments the production process by dividing formulations into individual bottle-level units rather than bulk production. Each bottle is filled independently with customized formulations, allowing high versatility while maintaining efficiency through automated sequential processing of each segment (bottle) through the fill line.
Solution Approach 2:
The system dynamically adjusts the dispensing process for each bottle based on real-time identification of container type and formulation requirements. The robotic arm and dispensing system can change parameters on-the-fly for each bottle, enabling flexible customization without sacrificing production throughput through optimized sequencing.
2Adaptability or versatility
If fixed packaging types are used in the dispensing system, then device complexity is reduced, but adaptability to different packaging requirements is limited
Solution Approach 1:
The system employs a universal robotic arm and dispensing platform that can handle multiple container types (glass bottles, plastic bottles, different SKUs) through a single fill line. The robotic arm is equipped with adaptive identification systems that recognize container types and adjust dispensing parameters accordingly, providing multi-functionality without requiring separate dedicated lines for each packaging type.
3Measurement precision
If manual verification of container types is performed, then measurement precision is sufficient, but productivity decreases
Solution Approach 1:
The system replaces manual verification with automated optical sensors and vision systems that rapidly identify container types and verify bottle placement. These electronic detection systems operate at high speeds consistent with automated dispensing rates, providing precise identification without becoming a bottleneck to production throughput.
4Loss of time
If bottles are sequenced without optimization, then device complexity is minimized, but loss of time increases due to inefficient fill line utilization
Solution Approach 1:
The system performs preliminary sequencing of bottles before they enter the fill line, optimizing the sequence based on formulation types and container characteristics. This advance organization ensures that bottles are arranged in an efficient order for the dispensing process, minimizing downtime and maximizing line utilization without requiring complex real-time adjustments during filling.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system achieves fast, flexible, and highly automated production of personalized hair dye kits with 100% traceability, minimizing downtime, and enabling the production of various SKUs concurrently with minimal efficiency loss, while ensuring accurate dispensing and quality control.
Implementation Method 1
the container obtained by the robotic arm has an embedded radiofrequency tag that stores information regarding the container type
Data Source
AI summary
A system is provided for dispensing a cosmetic container, comprising: a conveyer belt configured to transport a receiver container along a fill line; a robotic arm disposed at an ingress position of the fill line; a sensor disposed at an egress position of the fill line; circuitry configured to receive an order having a container type; control the robotic arm to obtain a container corresponding to the container type and place it a predetermined position on the conveyor belt at an entrance of the fill line; transit information of a sequence position of the container and the container type to the sensor; verify that the correct container is at the sequence position at the egress of the fill line after the container has been filed with a cosmetic product.