OPTIMA Moduline Smart

Fast, safe, and economical – with maximum modularity

Investment security, a groundbreaking operating and service concept, short delivery times, and high standardization – the new OPTIMA Moduline Smart delivers all this and more. This innovative machine is designed to adapt to evolving market needs while maintaining unparalleled efficiency. One of its early adopters is Louis Widmer, a Swiss manufacturer of premium cosmetics. At their facility, bottles and jars are processed across 14 formats. The Moduline Smart is pushing boundaries, including some unconventional ones. But what does this mean for the user?

Important for you

OPTIMA Moduline Smart: At a Glance

Medium output: Up to 60 containers per minute
Investment security: Rapid module replacement and expansion
Reduced footprint: 20–35% space savings
Short delivery time: From order to ramp-up in 4–6 months
Linear concept: Integrates up to three closure components

The project team of Louis Widmer SA (Andrzej Ochwat, Jürg Schmidhalter, Urs Eggen) together with Alrik Fischer (Technical Sales Manager at Optima Consumer). The machine was brought to Louis Widmer in July 2024 and was already in production a short time later. (Source: Optima)

A smarter way to fill

The OPTIMA Moduline Smart seamlessly handles bottle filling, different lids, closures, and fully automatic spray pump processing. “We also wanted to use the same machine to fill jars and seal them with sealed film,” explains Urs Eggen, Chief Operating Officer at Louis Widmer. Recognizing this need, Optima accelerated the development of the required module. “We had solved our business problem. Now the Moduline is really smart,” Eggen adds.

Additional modules are already in development, including a CIP (clean-in-place) module, a crimp function for fragrance bottles with spray pumps, and spin filling for highly viscous creams.

Investment security at its best

The OPTIMA Moduline Smart evolves alongside market demands. Modules can be added or replaced swiftly – often within days. This adaptability was crucial for Louis Widmer’s investment decision. Eggen recalls, “The question arose: What if we change our product range in six or seven years? Should we have a new product category, for example, pump dispensers instead of jars? The fact that we could replace a module quickly and not need to buy a completely new machine reassured the committee.”

The machine’s high quality is a given, and its cost-effectiveness stems from standardized modules and scalable production. These benefits extend to Industry 4.0 solutions and service packages, simplifying hardware and software installation. Reduced production costs are passed directly to customers, enabling Louis Widmer to integrate digital tools like WEmaintain for maintenance and OPAL for line management and efficiency analysis.

The new machine solution impresses with its high level of investment security, a new operating and service concept, short delivery times, and a high degree of standardization. (Source: Optima)

Detailed view in a filling machine for cosmetic products

Pluggable format parts enable quick and seamless format changes, making cost-effective production achievable even for small batch sizes. (Source: Optima)

Easy and safe operation

Addressing the skilled labor shortage, the Moduline Smart ensures straightforward operation through visualized processes, supported by internationally comprehensible images and videos. Eggen shares, “For the first time, I saw a machine manufacturer document every changeover and operation with pictures and videos. This means almost anyone can learn how to operate the machine.”

Processing 14 formats, filling volumes range from 25 ml to 250 ml. The machine manages intricate tasks, from straightening and inserting riser tubes in pump spray heads to sealing jars with aluminum and screw lids.

Built for flexibility

All cosmetic products are dispensed using rotary piston pumps, which are integrated via trolleys and equipped with SMED (Single Minute Exchange of Die) quick-change systems. Recipe-based adjustments are servo motor-supported, and all format parts are 3D-printed for rapid availability. The machine achieves an output of up to 60 containers per minute and was operational at Louis Widmer just 1.5 weeks after delivery.

The modular design ensures faster delivery times, adaptability, and long-term flexibility, as demonstrated by the Louis Widmer project.

Learn more about OPTIMA Moduline Smart

The OPTIMA Moduline Smart fills 14 different jar and bottle formats at Louis Widmer. The output reaches up to 60 containers per minute. (Source: Optima)

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