Cushion Compact Packaging Solution

Whether you run a single cushion foundation packaging product or a wide range of cushion foundation packaging, our complete cushion foundation packaging range of machines is excellent for companies dedicated to handling cushion foundation packaging precisely and aesthetically.

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Customer Pain Points

Problem Customer Faced

For Business (B2B)

Inability of Production Efficiency to Meet Market Demand?

Existing production lines are slow, lowly automated, with high failures and downtime, yielding insufficient output. They can't handle surging orders or rapid new launches, bottlenecking growth. Symptoms: slow cycles, poor machine coordination, heavy manual intervention.

High Energy Consumption and Maintenance Costs of Traditional Equipment?

Older equipment uses inefficient drives (pneumatic, high-power motors) and wear-prone structures, wasting electricity and air. Frequent repairs raise costs for parts, technicians, and services, keeping maintenance expenses high.

High Defect Rate Caused by Poor Equipment Stability?

Poor accuracy, complex setups, and fluctuations cause defects: inaccurate filling, loose caps, misaligned labels, bad seals, damaged film. High defects waste materials, add rework labor, raise costs, and damage brand reputation.

For B2C Clients

Large Equipment Footprint, Cannot Fit in the Workspace?

Traditional equipment prioritizes function, resulting in bulky designs. SMEs and creators face limited workshop/studio space; oversized machines can't fit or encroach on operations, preventing automated production implementation.

Difficulty Achieving Small-Batch Production?

Large lines suit mass single-item production but require lengthy, labor-intensive changeovers. SMEs need frequent switches for varied, small-batch products; replacing molds and adjusting parameters takes hours, with high costs, unfit for flexible manufacturing.

Complex Equipment Operation Requires Specialized Skills

Complex interfaces with jargon intimidate users, demanding extensive training. SMEs lack engineers, facing high costs, operational risks, and reliance on external support for issues.

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Why Choose Us

Cushion Compact Packaging Line Technical Highlights

Dual-Mode Precision Filling & Puff Assembly

Addressing cushion foundation's paste or liquid formulation, the line utilizes a dual-servo piston pump or micro peristaltic pump filling system to achieve ultra-high accuracy, effectively managing material costs. After filling, a robotic vision system precisely positions and presses the sponge cushion or puff into the compact, ensuring flatness and sponge absorption consistency. The entire line is centrally managed by a PLC, synchronizing filling, cushion assembly, and automatic lid closing at high speed.

Multi-Component Precision Assembly & High-Speed Clamshell Closing

Cushion packaging involves assembling up to five components (base, mirror, inner lid, outer lid, and cushion insert). The line uses a multi-station rotary or linear assembly system to efficiently complete mirror hot melt mounting, cushion insert pressing, and automatic inner lid sealing/closing. A customized high-torque capper ensures the outer compact is closed securely without damaging the surface. The flexible design allows for rapid switching between various unconventional shaped compacts, such as round or square.

High-Resolution Vision Inspection & Defect Rejection

The line integrates a high-resolution vision inspection system for real-time monitoring of all critical stages. This includes checking the filling weight compliance, cushion surface for bubbles or spillage, mirror/puff integrity, compact surface for scratches, product label placement accuracy, and lid closing torque. All defective products are automatically rejected. The system is also equipped with an MES interface to achieve full-process quality traceability of the production line.

High-Speed Cartoning & Secondary Packaging Automation

The assembled cushion compacts are picked up by a high-speed automatic cartoner to complete case erection, product insertion, and sealing (either tuck-in or hot melt glue). The line seamlessly integrates with an overwrapping machine for heat-shrinking or transparent film wrapping of individual compacts, enhancing perceived value and anti-counterfeiting features. The end-of-line process is handled by an automatic case packer and a robotic palletizing system for secondary packaging and logistics preparation, dramatically improving shipping efficiency.

Modular Design & Smart O&M Management

The entire line features a highly modular and open design for easy maintenance and future expansion, while supporting quick changeover. The system integrates a cloud monitoring platform enabling equipment predictive maintenance, energy management, and remote diagnostics. The smart control strategy allows for the storage of 50+ recipe and specification parameters, allowing operators to recall them with a one-touch call, significantly streamlining the O&M process.

Custom Design

Personalized Customization Solutions

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Meet the flexible production needs of small and medium batches of air cushions

For small-to-medium batches and new product trials, we offer economical semi-automatic filling machine combinations or compact fully automatic equipment. These machines emphasize quick changeover capability; switching between different cushion compact or packaging formats requires only minimal fixture changes and parameter adjustments, significantly saving time and production costs, ideal for flexible production.

Can be adapted to various special-shaped air cushion containers such as round and square

Our cushion packaging equipment features powerful multi-container adaptability. Beyond common round cushion compacts, we can handle various packaging types like unconventional shaped compacts, soft tubes, and pouches. We provide corresponding high-precision clamping, positioning, and conveying solutions for each container, ensuring stable operation across the entire line, from filling to automatic lid closing, especially for cushion insert assembly precision.

"Integrated Line Customization" Service for Cushion Production

Our core advantage is providing the "customized integrated packaging line" service. Based on the client's specific cushion paste process requirements, we seamlessly integrate equipment such as the filling machine, capping/lid-closing machine, labeling machine, cartoner, wrapping machine, case packer, and palletizer. We deliver a complete automated solution covering the entire process, from product filling to final robotic palletizing, optimizing the complex cushion assembly process.

How To Choose

How to Choose Your Machine: What You Need to Know

1.Is Your Cushion Formula Paste or Liquid, and What is the Viscosity?

The material characteristics of your cushion foundation are critical for selecting the filling system. Is your formula a high-viscosity paste base or a free-flowing watery base? Paste formulas often require a servo piston pump or pressure filling to ensure ultra-high accuracy. Furthermore, active ingredients in the formula may necessitate nitrogen protection to maintain product stability and prevent oxidation during filling.

2.What Components and Assembly Methods Are Involved in Your Cushion Packaging?

Cushion packaging typically involves multiple components like the base, mirror, cushion insert, puff, and inner/outer lids, necessitating complex multi-station assembly. You need to confirm if mirror hot melt mounting, automatic puff assembly, and automatic inner lid closing/capping are required. These needs determine whether the line must integrate a robotic vision system for positioning and a customized high-torque capping machine to ensure compact sealing and integrity

3.What Is Your Plan for the Cushion Production Line's Output and Packaging Speed?

Your target output dictates the line configuration and investment scale. As a popular cosmetic, market demand may require large-scale production (e.g., 2000 boxes/hour or more). You need to decide between a semi-automatic solution for R&D and small batches, or a high-speed integrated line to achieve maximum capacity. The line must possess quick changeover capability to adapt to market demands for multiple specifications.

4.What Level of Automation Does Your Budget and Goal Require?

The choice of automation level relates to your budget and long-term benefits. Do you require a basic semi-automatic filling solution with manual cartoning , or the highest-tier fully automatic solution, achieving unmanned operation from compact feeding, filling, automatic labeling, to robotic case packing and palletizing? The fully automatic integrated line solution, while requiring a higher initial investment, delivers the best ROI through increased efficiency and labor cost reduction.

5.Are There Special Constraints Regarding Your Production Space and Process?

Large cushion packaging lines must consider space dimensions and layout, potentially requiring a U-shaped or linear layout to fit physical constraints. Furthermore, the equipment design must comply with GMP standards and cleanroom standards to ensure hygiene and safety. Additionally, the line should support mixed production of multiple specifications and a recipe memory system for flexible production management.