COSMETICS & HYGIENE
Boccard’s Integrated Process Solution for Tatra Spring
As cosmetics production scales up, increasing the capacity of individual pieces of equipment is no longer enough. Automation, production flexibility, efficient material and product flows, effective CIP cleaning, and the integration of all process stages into a single system become essential.
Tatra Spring, a cosmetics manufacturer and part of the international Intercos Group, faced the challenge of moving from production based on standalone equipment to a fully integrated production environment.
The solution was a complete process installation delivered by Boccard Polska. The project integrated raw material handling and storage, mixing, product storage, transfer to the packaging line, automated CIP cleaning, and process control into one seamless production process.
From a Standalone Mixer to a Complete Production System
An Integrated Production Model
Previously, production at Tatra Spring was based on a standalone mixer, also supplied by Boccard. The new project marked a shift towards a far more integrated production model.
The goal was to create a single system covering the entire process, from raw material receiving through to the transfer of the finished product to the packaging line.
- 6 raw material and finished product storage tanks
- 1 process mixer with a homogenizer
- 7 modular skids
- Raw material unloading and storage system
- Transfer systems and product transfer installation
- Integration of the process installation with the packaging line
- Heating and cooling, vacuum, CIP and chemical dosing skids
- Service platforms and a comprehensive control system
How to Increase Flexibility in Cosmetics Production
Efficient Raw Material and Production Management
One of the project’s key objectives was to increase production flexibility. Tatra Spring gained four storage tanks that were not previously available, enabling production to be prepared in advance and batches to be managed more efficiently.
Previously, materials were unloaded into 1 m³ IBC containers, with individual connections made manually. The new installation features large raw material storage tanks and a dedicated transfer system. This reduces manual operations, supports production continuity, and lowers the risk of errors.
The installation was designed to handle products with a wide range of viscosities, from water-like liquids to thick, high-viscosity creams.
How Is a Complete Cosmetics Production System Designed?
Designing the Process as an Integrated Whole
A complete process installation takes shape long before equipment installation begins at the production site. The first step is to develop the process concept and define how the entire system will operate. The equipment, piping, support structures, and the space required for operation and maintenance are then designed.
All these elements are incorporated into a 3D model, providing a detailed representation of the future installation before assembly begins. This model is then used to prepare workshop documentation, layouts, cross-sections, and bills of materials.
This approach makes it possible to view the facility not as a collection of standalone machines, but as one fully integrated production process.
Why Do Modular Skids Improve Process Installation Delivery?
The project included seven skids, complete modular equipment units covering functions such as raw material transfer, CIP, valve manifolds, product transfer, and chemical dosing.
The skids can be assembled and tested before final installation on site. This was particularly important for the Tatra Spring project, as the work was carried out within an operating production facility.
How Does Automation Transform Cosmetics Production?
The new installation integrates the mixing process with product transfer and auxiliary systems. The control system monitors process parameters, tracks product batches, manages transfers, and controls cleaning cycles. The new equipment has also been integrated with the plant’s existing control systems.
As a result, both new and existing equipment can operate within a single control architecture, while operators manage the process via operator panels. Automation connects the individual process stages and makes day-to-day production more predictable and consistent.
Why Is Automated CIP Important in Cosmetics Production?
One of the most important changes at Tatra Spring was the implementation of an automated CIP (Cleaning-in-Place) system. Previously, cleaning was carried out using a mobile pump and manually connected hoses, making the process time-consuming and inefficient. The new system is fully automated and integrated directly into the process installation.
The CIP station is equipped with three tanks, configured based on an analysis of the plant’s processes and actual production requirements.
The introduction of automated cleaning and sanitisation in a closed-loop system has helped to:
- reduce water consumption,
- reduce wastewater generation,
- reduce detergent consumption,
- shorten downtime between production batches,
- maintain consistently high cleaning standards.
What Was the Scale of the Project?
A complete installation involves more than the equipment visible on the production floor. It also represents thousands of hours of engineering, manufacturing, installation and programming.
142 | designed pipelines |
402 | installed fittings |
2,235 | complete assemblies produced on site |
approx. 13,651 hours | total project hours |
2,455 hours | engineering and documentation |
8,348 hours | construction and manufacturing |
1,692 hours | automation and electrical work |
1,156 hours | supervision |
What results did the new installation deliver?
The most important result is the increase in Tatra Spring’s production capacity. Plant efficiency increased by 50%.
Integrating mixing with filling also shortened the overall production cycle, while the new installation enables a broad range of products with different characteristics to be manufactured.
The plant can produce approximately 2.5 million bottles per month, equivalent to around 30 million bottles per year. At the same time, automated CIP improved the cleaning process and reduced water and detergent consumption as well as wastewater generation.
The Tatra Spring project in figures
+50% |
production capacity
|
approx. 2.5 million | bottles per month |
approx. 30 million | bottles per year |
6 | tanks |
1 | mixer |
7 | modular skids |
3 | tanks in the CIP station |
approx. 7–8 months | from contract signature to line start-up |
From Standalone Equipment to a Fully Integrated Production Facility
The Tatra Spring project shows that increasing cosmetics production capacity is about more than simply adding new equipment.
The key is to integrate raw material handling, storage, mixing, product transfer, CIP, auxiliary systems, and automation into one seamless process.
This approach enables manufacturers to move from production based on standalone equipment to a fully integrated production environment that can support higher production volumes, a wider product range, and the plant’s future growth.
Feel free to contact us to learn how we can support your next Cosmetics & Hygiene project.
Frequently Asked Questions (FAQ)
What is CIP in cosmetics production?
CIP, or Cleaning-in-Place, is a system that enables process equipment to be cleaned without dismantling it. At Tatra Spring, the previous solution based on a mobile pump and manually connected hoses was replaced by an automated CIP system integrated directly into the process installation.
How can cosmetics production efficiency be increased?
One of the key factors is the integration of all process stages, including raw material handling, mixing, storage, product transfer, CIP, and automation. At Tatra Spring, implementing a complete process installation resulted in a 50% increase in production capacity.
How can flexibility in a cosmetics production facility be increased?
Greater storage capacity, automated transfer systems, and an installation designed to handle products with different characteristics make it easier to manage a diverse production portfolio.
Can one installation handle products with different viscosities?
Yes. The installation was designed to handle a wide range of products, from low-viscosity liquids to thick, high-viscosity creams.
What does a complete process installation for the cosmetics industry include?
The scope can include raw material receiving and storage, mixing, product storage, transfer systems, CIP, heating and cooling, vacuum systems, chemical dosing, automation, and integration with the packaging line.
KEY HIGHLIGHTS
+50% production capacity
Approx. 2.5 million bottles per month
Greater production flexibility
Ability to handle products ranging from liquids to thick creams
Fewer manual operations
Shorter downtime between batches
Reduced water and detergent consumption
Less wastewater generated
One fully integrated production process
Boost Your Production Capabilities with Boccard
Growing cosmetics production today requires more than high-performance equipment. Above all, it requires a well-designed, fully integrated process. Boccard brings together process technology, engineering, equipment, piping, automation and CIP systems to deliver complete installations tailored to the needs of cosmetics and personal care manufacturers.
Are you planning to increase production capacity, automate your processes or upgrade an existing installation? Talk to Boccard experts about a solution tailored to your production facility.
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