For over 13 years, the OPTIMA Moduline has been one of the big stars at Optima Consumer and adds flexibility to filling and closing cosmetics products thanks to its high degree of modularity. And all this with an output of at least 100 products per minute. At Interpack 2023, Optima presented a new variant of the successful machine – the OPTIMA Moduline Smart. Over 150 systems based on this machine platform have already been sold. Therefore, it's only fitting that we should ask: How did the success story start? What were the milestones? And what exactly makes the Moduline so successful?
One example of Optima's innovative power is the new OPTIMA Moduline Smart filling and closing system for cosmetic products, which was introduced at Interpack for the first time. It will be setting new standards in terms of space requirements, format flexibility and delivery times. The Moduline machine concept stands for unparalleled flexibility: quick format changes, large format ranges, the processes that can be expanded and changed with plug and play and a wide range of special functions are all reasons for its success.
But first let's take a step back. It all began in 2010. The first OPTIMA Moduline was delivered, which was based on the Linoline machine platform. The very first project set new standards: Personalized perfumes with a batch size of one were filled. The development shifted from a fixed machine plate to a flexible module arrangement; multiple stations could be installed.
The Moduline grew beyond its own limits in 2013. The first system with the flexible SRS transport system was delivered. The recipient was a traditional cosmetics company based in Germany. For sensitive cosmetics, a Laminar-Flow unit is added to the Moduline to fulfill the highest hygiene requirements. This was used for the first time in combination with the Moduline.
One milestone was the introduction of a frame rack in 2015. This enabled robot solutions to be integrated, advancing the Moduline even further in terms of modularity and flexibility. Extremely flexible applications were now possible.
The further developed Moduline was a true media sensation at the Hanover trade show 2015. The machine on display at the trade show with Siemens can configure an individual perfume from a wide variety of components – the bottle, label, fragrance composition and cap. This also includes customization or individual brand design. The first customer was none less than former German Chancellor Angela Merkel.
In 2017, the OPTIMA Moduline conquered the extremely demanding Cosmeceuticals segment – cosmetics with active ingredients with health benefits – at a French company. And these were even two-phase products consisting of cleansing and skincare ingredients that cannot be mixed due to their chemical properties. Only by shaking the container shortly before use does the mixture become ready for application. The important factors here were the high dosing precision due to the valuable ingredients and the enhanced hygiene functions like a Laminar-Flow unit and 3.1 certificates. More information is available at: Cosmeceuticals from Pierre Fabre
The OPTIMA Moduline Smart sets new standards in terms of space requirements, format flexibility and delivery times. This is more than just a claim – it's based on knowledge of the requirements of our cosmetics customers built up over many years.
In 2021, we went back to the roots: The OPTIMA Moduline Classic was launched and brought the initial machine concept to life. Like before, the system was based on a mounted stainless steel frame, offered more options for standardization and thus enabled shorter delivery times. "The higher levels of standardization means that the investment costs are manageable with tried-and-tested Optima quality and high output rates of 60 to 120 products per minute", says Alfred Weihbrecht, Director Sales Cosmetics & Chemicals. The Classic is usually used in the high performance range from 100 to 120 products per minute. It is possible to expand the systems at any time due to standardized interfaces.
The real show-stopper came at Interpack 2023: Optima Consumer presented the OPTIMA Moduline Smart. What had changed? The system offers even greater standardization, the delivery times and the whole time-to-market are significantly shorter. Optima's expertise in the high performance segment has been incorporated into the development of the new system. The Optima Consumer business unit thus expanded its system portfolio in the medium performance segment. Initially, the system will process 60 products per minute, with an expansion to 120 products per minute planned for the future. The footprint has been reduced even further compared to the OPTIMA Moduline Classic. This is a key benefit, as space it often limited at the customer premises. Together with the digitalization features from the OPTIMA Total Care service portfolio, the OPTIMA Moduline Smart has become the new flagship of the Moduline series.
What's the recipe for success behind the Moduline series? "Without a doubt the modularity", replies Heiko Kühne. "It offers our customers maximum flexibility and investment security compared to star machines, for example." The free arrangement of different functions in combination with short delivery times was, is and remains the perfect response to frequent new product launches in the cosmetics market. With the OPTIMA Moduline Smart, the success story of the Moduline series is therefore set to continue for a long time to come.