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Boosting Liquid Filling Efficiency in Ethical Haircare Production: Herb UK
How Herb UK transformed their production efficiency, consistency, and ability to scale ethical haircare manufacturing with the CC570 Liquid Filling Machine.
Herb UK is a proud British manufacturer specialising in professional-grade haircare products that are as kind to the planet as they are to your hair. The company’s range is cruelty-free, vegan-friendly, and made with certified organic and natural ingredients sourced from ethical suppliers. Their commitment to sustainability doesn’t stop at what’s inside the bottle, every bottle and box is made from 100% recycled materials, reinforcing Herb UK’s mission to reduce environmental impact across every stage of production.
This passion for ethical craftsmanship has earned Herb UK a loyal customer base and a respected reputation within the professional haircare industry. But as demand grew, their production setup began showing its age. Their existing filling equipment could no longer keep pace with output demands, nor could it handle the diverse range of product viscosities across shampoos, conditioners, and hair colour formulations.
To maintain their high standards of consistency and sustainability, Herb UK needed a modern solution, one that would deliver precision, reliability, and efficiency without compromising their values.
Inconsistent Fills and Inefficient Changeovers
Herb UK’s previous automatic liquid filling machine had become increasingly unreliable. Fill volumes were inconsistent, the equipment struggled with thicker products, and product changeovers were cumbersome and time-consuming. Each setup required manual intervention, leading to downtime and delays in production schedules.
The situation posed multiple challenges:
- Inconsistent Fill Volumes: Variation between bottles resulted in waste, rework, and quality control issues.
- Viscosity Limitations: Thicker formulas, such as conditioning treatments and hair dyes, exceeded the old system’s capabilities.
- Slow Changeovers: Adjusting for different product types or container sizes took too long, reducing overall line efficiency.
- Reliability Concerns: Frequent maintenance needs led to costly interruptions and frustrated production staff.
Team needed a solution that could not only solve these immediate problems but also scale with future demand, a liquid filling machine that offered precision, flexibility, and ease of use.
The Search for a Better Solution
Herb UK explored several machinery options but struggled to find one that balanced engineering precision with practical usability. They required more than just new equipment; they needed a long-term partner who understood their production challenges and could deliver a machine designed around real-world performance.
That’s where Cap Coder came in. Known for its UK-designed and built filling and capping machines, Cap Coder combines robust engineering with responsive, human-centred support. For Herb UK, this partnership was a natural fit. A fellow British manufacturer that shared their dedication to quality, integrity, and responsible practices.
The Cap Coder Approach
Cap Coder proposed the CC570 Multiple-Head Inline Liquid Filling Machine, a high-performance system designed to improve both accuracy and efficiency across Herb UK’s diverse products.
Key Features and Benefits
- Twin Servo-Driven Volumetric Gear Pumps:
Ensure every bottle is filled to exact specifications, with the flexibility to handle multiple viscosities. - Positive Pneumatic Shut-Off Nozzles:
Prevent product drips during filling, reducing waste and maintaining a clean production environment. - Servo-Driven Nozzle Lift System:
Enables exact control of nozzle movement, ensuring smooth, consistent fills even with foamy or viscous formulations. - Recipe-Based Automation:
Operators can store and recall product recipes on the machine’s intuitive HMI (Human-Machine Interface). Each recipe captures parameters such as pump speed, nozzle position, and fill volume. This allows rapid changeovers between products. With just the press of a button, dramatically reducing setup time and operator training needs. - Inline Integration:
The CC570 filler is designed to fit seamlessly over an existing conveyor, allowing Herb UK to integrate the new system into their current production layout without major disruption.
This bespoke configuration was developed to meet Herb UK’s exact product and workflow requirements. The result was a system that not only solved their original challenges but added new levels of control and efficiency to their liquid filling operations.
Implementation and Support
Cap CFrom the first consultation to installation and training, Cap Coder’s engineering team worked closely with Herb UK’s production staff to ensure a smooth transition. Samples of shampoos, conditioners, and dyes were used to fine-tune filling profiles and ensure consistent results across the full product range.
Cap Coder’s hands-on process ensured that the liquid filling machine was fully operational within days, minimising downtime. Their after-sales support, including remote diagnostics and on-site service options, provided additional peace of mind, ensuring the new liquid filling line would perform reliably for years to come.
Transformative Results
The installation of the CC570 has been transformative for Herb UK’s production line.
1. Improved Accuracy and Consistency
The twin servo-driven gear pumps deliver precise, repeatable fills, even with thicker or aerated liquids. Product waste has been significantly reduced, and every bottle now meets the same high-quality standards expected from a premium brand.
2. Faster Changeovers
Recipe storage on the HMI has streamlined setup between different formulations. What once took significant manual effort can now be done in minutes, improving overall line efficiency and uptime.
3. Enhanced Flexibility
The system’s programmable controls allow Herb UK to run a wide variety of products, from lightweight shampoos to rich, viscous conditioners without the need for additional hardware changes. This versatility ensures their filling line remains future-proof as new products are introduced.
4. Reduced Downtime and Maintenance
Cap Coder’s robust engineering and precision components mean fewer stoppages and lower maintenance requirements. Operators have reported smoother operation and greater confidence in daily performance.
5. Sustainability in Action
Beyond productivity, the new setup supported Herb UK’s sustainability goals. Accurate dosing helps reduce material waste, while improved efficiency lowers overall energy consumption. These are small but meaningful gains in their ongoing mission to minimize environmental impact.
The Customer Experience
James Archer, Operations Manager at Herb UK, summarised the impact:
The CC570 Filler has met all our requirements and expectations, and production efficiency has been greatly improved. Beyond the numbers, what stood out most was Cap Coder’s collaborative approach. From initial consultation to after-sales support, the team demonstrated a clear understanding of Herb UK’s goals and constraints, providing practical, tailored engineering solutions rather than off-the-shelf answers.
What Makes Cap Coder Stand Out
Herb UK’s decision to partner with Cap Coder was based on more than technical specifications. It was about trust, expertise, and shared values.
- UK Engineering Expertise: All Cap Coder machines are designed and built in the UK, ensuring quality, support, and quick response times.
- Bespoke Solutions: Every system is tailored to the customer’s product and production process.
- Human-Centred Support: Cap Coder’s team of engineers and technicians bring both expertise and approachability, a combination that makes complex automation feel simple.
- Future-Ready Design: Scalable systems with easy upgrade paths help customers grow their production capabilities without full reinvestment.
For Herb UK, this partnership provided more than a reliable new filling machine, it delivered confidence that their production line could keep up with demand, uphold product integrity, and align perfectly with their brand values.
Cap Coder: Your Expert Partner in Filling and Capping Solutions
Herb UK’s journey reflects the strength of pairing expert manufacturing with intelligent automation. By upgrading to the CC570, the company achieved the reliability, flexibility, and precision it needed to maintain its high standards while increasing output.
Cap Coder’s engineering expertise has given Herb UK the tools to grow sustainably delivering cruelty-free, vegan haircare products efficiently and confidently.
For Herb UK, the results speak for themselves: smoother operations, consistent quality, and a trusted automation partner ready to support the next stage of their success.
Ready to partner with Cap Coder? Get in touch with our experts today and let’s make it happen!
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