The Drive for Global Standards

In the competitive landscape of personal care manufacturing, the transition from domestic success to global export requires more than just a good product – it demands impeccable packaging precision. For Vi-John, a household name in India, maintaining their reputation for quality while scaling up for international markets was a priority. To achieve this, they needed a High-Speed Tube Filling and Cartoning Solution that could deliver consistency, speed, and reliability.

Vi-John was already a satisfied customer, utilizing WIMCO by Stelda’s PAC machines for their existing lines. However, a specific challenge arose with their tube filling operations for export products. Their journey to upgrade their facility led them to the powerful combination of the WIMCO GAN 120 and PAC 120, a decision that completely transformed their production capabilities.

The Bottleneck: Struggles with Legacy Equipment

Before integrating the new WIMCO line, Vi-John was facing significant hurdles with an older, rotary-style machine from a manufacturer named Paras. While this legacy machine had served them in the past, it was becoming a liability for their expanding ambitions.

According to the sales team handling the account, the older machine was plagued by maintenance and operational issues. It was a second-hand purchase that was being serviced locally, leading to frequent downtime and a lack of spare parts availability. More critically, the machine suffered from technical inconsistencies:

• Weight Variation: The fill accuracy was fluctuating, which is unacceptable for strict export regulations.

• Orientation Issues: Tube alignment was inconsistent, affecting the visual appeal of the final product.

• Sealing Integrity: “Sealing proper nahi aane ka issue tha” (There were issues with improper sealing), which compromised product safety and shelf life.

These defects meant Vi-John was not comfortable using the legacy line for their export-bound products. They needed a robust High-Speed Tube Filling and Cartoning Solution to eliminate these risks.

The Solution: Precision Engineering with WIMCO GAN 120

To address the quality gaps, Vi-John replaced the problematic line with the WIMCO GAN 120, a double-head tube filling and closing machine designed specifically for high-accuracy production environments.

The GAN 120 solved the weight variation and sealing issues instantly. Engineered with a Ferguson drive system, it ensures smooth mechanical operation, which is crucial for maintaining consistent fill weights even at high speeds. The machine features a “No Tube, No Fill” logic that drastically reduces wastage – a key factor for a company focused on efficiency.

Unlike the older rotary machine, the GAN 120 offers adaptive sealing options, compatible with hot air, crimping, and combination formats. This versatility allowed Vi-John to handle various tube materials – whether metal, laminated, or plastic – ensuring that every tube leaving the factory met the stringent aesthetic and functional standards required for international markets.

Seamless Automation with the PAC 120 Cartoner

A premium tube needs a premium carton. To complement the filling prowess of the GAN 120, the line was integrated with the WIMCO PAC 120, an automatic carton erection and closing machine.

The PAC 120 is built for rugged durability and high-speed operation, capable of handling up to 120 cartons per minute. This matched the output of the tube filler perfectly, creating a synchronized High-Speed Tube Filling and Cartoning Solution.

Key features that enhanced Vi-John’s operational efficiency included:

• Smart Safety Logic: The machine utilizes “No product/no carton” and “No leaflet/no carton” systems, ensuring that no empty or incomplete packages ever reach the shipping pallet.

• Versatility: It supports both reverse and straight carton tucks, offering flexibility for different product SKUs.

• Durability: Clad in SS 304 guards, the machine is GMP-compliant, aligning perfectly with the hygiene standards expected in the cosmetics and personal care industry.

Why Vi-John Chose WIMCO for Exports

The decision to invest in this specific High-Speed Tube Filling and Cartoning Solution wasn’t just about fixing a broken machine; it was about trust. Vi-John’s management was already “satisfied with PAC” (the previous machine they owned). They knew that WIMCO machinery delivered on its promises of longevity and performance.

By switching to the GAN 120 and PAC 120, they eliminated the reliance on local, unreliable service for their critical machinery. The WIMCO lines come with centralized lubrication systems to minimize maintenance and are backed by a reliable supply of spare parts, solving the obsolescence issue they faced with the Paras machine.

The Result: Ready for the World

Today, Vi-John operates with a confidence that was previously missing from their export division. The weight variations are gone, the tube orientation is precise, and the sealing is flawless.

The integration of the GAN 120 and PAC 120 provided them with a High-Speed Tube Filling and Cartoning Solution that acts as a single, cohesive unit. This success story highlights a critical lesson for manufacturers: when targeting global markets, the cost of unreliable machinery is far higher than the investment in quality engineering. With WIMCO, Vi-John has secured a production line that is as premium as the products they sell.

Elevating Manufacturing Standards

Vi-John’s success story serves as a testament to the importance of precision engineering in the personal care industry. When export regulations and brand reputation are at stake, there is no room for “approximate” measurements or inconsistent seals. Through the deployment of WIMCO’s High-Speed Tube Filling and Cartoning Line, Vi-John has not only solved their immediate production challenges but has also future-proofed their facility for the demands of the global market.