WECKERLE GMBH

About Us

From a small precision engineering workshop to a world-wide recognised specialist in the field of sticks and tube filling machine manufacturing. For more than 30 years Weckerle has been the global leader in Cosmetic Machine Manufacturing.

Weckerle GmbH was founded in 1965 by Peter Weckerle and has developed from a small precision engineering workshop to a worldwide operating company with a leading position in the field of filling machines.

With the invention of the world’s first fully automatic lipstick moulding machine Weckerle entered into the market of cosmetic processing and was soon well-known in this field, enjoying an excellent reputation with its’ customers. Weckerle first began to develop its world famous name for filling machines in the early 1970s. We were among the first pioneers in automatic lipstick filling machine manufacturing and soon become involved in overseas markets. By the 1980s Weckerle’s filling machines were in use throughout the world.

We are a well-established German producer of lip / slim stick and high-speed tube filling and packaging machines for the cosmetic, pharmaceutical and food industry.

During the years we also developed machines for filling make-up powder, nail polish, deodorant sticks, cosmetic pencils, chap sticks, glue sticks, tubes, etc. Our customers are spread all over the world and all our machines are designed to each customer’s specification. Customers can choose between standard machines and highly specialized machines constructed according to their respective demands.

With headquarters in Germany and offices in Brazil, the United States and Switzerland the company is recognized world-wide for its state-of-the-art, automatic, high-speed filling machines for lipsticks, lip balm sticks, eyeliner pencils, eye shadow pencils and also tube-filled products.

Since 1968, the most prestigious companies in the cosmetic industry, including L’Oreal, Christian Dior, Estée Lauder, Maybelline, Max Factor and Avon have entrusted Weckerle to deliver precision products and services at competitive prices.

We have always concentrated on research and development in response to demands for greater speed and reliability, always identifying new user requirements and adapting our machines accordingly.

We improved and expanded not only our product range, but also our service network, offering complete customer support.

Our machines comply fully with all the common safety regulations worldwide. At the start of the new millennium the climate of the filling machine industry was experiencing rapid change and competition fundamentally influenced the market. We responded by delivering a completely new machine generation, competitively priced with even further improved quality.

The result was the revolutionary Multimould concept launched in 2002. It provides not only a high technical standard with excellent design but also brings together every aspect of filling machine experience and design expertise, incorporating the latest in development and production technology in order to satisfy market demand for higher quality with lower costs.

We have always played a leading role in the development of filling machine design and manufacture. We have always met the needs of our customers and have responded with technical innovation and new product introductions to meet ever greater demands.

Today, Weckerle GmbH in Weiheim, Bavaria, Germany, produces a variety of filling and processing machines not only for the cosmetic but also for the pharmaceutical and food industries. 85% of all lipsticks produced worldwide are made on Weckerle machines by more than 350 of our lipstick machines.

We have a global workforce of approximately 240 people, 65 of them in the machines manufacturing plant in Weilheim, Bavaria.

Weckerle’s success and stature are the result of two factors that distinguish the company from others in the field of filling machine manufacturing for the cosmetic industry. First, Weckerle is the source of innovation for the entire field. Peter Weckerle, the company’s founder, invented Weckerle’s moulding machines, the most widely used in the industry.

Mr. Weckerle is also credited with introducing mechanical liner pencils to the cosmetic world. He personally oversees all the company’s technical development and the future design of its machinery. In the past few years his son Thomas Weckerle took over his day-to-day responsibilities and is now the company’s owner and CEO. Second, Weckerle is a vertically integrated company, controlling the entire process from production to delivery.

Weckerle sales professionals are precise with their details and flexible in delivering service because each one has an intimate knowledge of the company’s own machinery and processes.

In the future WECKERLE will continue to develop and optimise its filling systems to meet the changing needs of its customers.

Recent History and Company Highlights

2004-2005
Development and launch of new Weckerle Cartoning Machine

2005-2006
Development and launch of new Weckerle moulding table for lipstick filling machines with dockable chambers for quick and easy format change.

2006 Highlight
Development and launch of new Weckerle FAL060 flexible assembly line for lipstick filling and Hotfill machines. The main advantages of this FAL 060 are its flexibility, modularity and quick format change. It can be combined with labelling, cartoning and sleeving machines.

2006-2007
Development and launch of the new Weckerle Hotfill filling and assembly line. The Weckerle Hotfill filling line is designed for the utmost flexibility due to its modular machine concept (mechanical and   electrical) and its quick colour change. A great variety of products can be produced with this Hotfill filling machine, such as mascara, lip gloss, lip and eyeliner and cream powder and even swirl products can be filled. A wide range of packaging material can be filled, such as pans, jars, tubes, boxes and deodorant sticks. Machine stand stills are minimized.

Lipstick Filling Machine

We are the leading manufacturer of high-quality cosmetic stick filling and packaging lines (for lipsticks, lip balm sticks, lip liners, eye liners, slim- sticks, deodorant and glue sticks etc.) as well as high-speed tube filling and packaging machines. Furthermore, we produce machines for filling powder, crème powder, make-up, mascara, lip-gloss and nail polish etc. All our machines are adapted to the individual demands of your customers. We are a well established German family enterprise which was found over 30 years ago with subsidiaries in many countries such as Germany, Switzerland, USA, Brazil, France and Russia. Our first machine was a lipstick filling machine and during the time we developed and launched many further machines in premium quality. Our customers are well-known and famous global players of the cosmetic and pharmaceutical industry as well as of the food and office supply (stationary) industry world-wide.

MM180 Lipstick Filling Machine

- Output: Up to 3,600 pcs/h
- Operators: 1 to 2 persons
- Product: Any

Fully servo driven high quality lipstick filling and assembly machine with 180 interchangeable moulds (made to customer’s specification) carried in a rotary table for any hot poured cosmetic sticks (lip sticks, lip balm sticks, make-up sticks).

The moulds are heated / cooled by temperature controlled water circulation systems. Our MM180 lipstick filling machine could also be equipped with our new flexible assembly line FAL60, labelling machine, cartoner, and sleever. The main advantages of this brand new FAL60 module are its flexibility, modularity, and quick format change. This assembly line can also be used on hot filling and bottle filling machines.

MM180, New Technologies Features:

MM Filling Machines

Silicone mould, blow-out mould, and push-out mould with automatic change in the ejection unit. The machine is made for utmost flexibility; all three-mould technologies can be used in one moulding table. The mould change time is dramatically reduced because of the new quick exchange chamber system. The change time for the pomade ejection unit is reduced to zero by using the servo motor driven ejection unit. The machine allows producing pomades in a diameter range from 3 mm to 22 mm. With the multi transfer system back filling of lipsticks and filling of bottles can be done.

Automatic Mould Cleaning

Metallic mould cleaning time is dramatically reduced by installing the new Automatic Mould Cleaning system. The entire moulds are fully automatically cleaned during shade change.

MDS System

The MDS (Melting and Dosing System) provides efficient filling. The melted lipstick bulk directly flows out of the tank to the dosing pump. This provides short cleaning time and perfectly homogenous product for dosing. Product melting time is reduced because of stirring motion during melting from the very beginning.

The level detection allows having an automatic speed control. Depending on the product level the stirrer is automatically adapted to the required speed. Creating bubbles or separation during stirring is absolutely prevented.

The colour is changed by pressing a bottom on the HMI. Vessel and dosing pump is completely changed. Change time is less than 1 minute.
The system can be optionally equipped according to product needs for filling even special bulks.

All moulding parameters are archived in the machine control.
With the dockable tank system the vessel and the tank (including all controls) can be transferred as one unit on a cart to the bulk production area.

Temperature profiles display

With this new feature the moulding process becomes more transparent. The moulding temperature profile as it is on the mould is displayed on the HMI. So scale up from a MM060 to the MM180 production machine is dramatically supported. Bulk texture and its creation can be controlled much better.

Efficiency Recording System

This new tool records all start and stops of the machine including stop reason. With the graphical analysis the operator clearly sees where efficiency can be improved.

Servo Controllers Winding Systems

The new winding system provides utmost sensitivity to lipstick mechanism. The absolutely reduced inertia the servo controlled winding unit turns the godet in the defined end or defined in-between position.

Benefits of MM180

Flexibility due to:

• Fully automatic double dosing station
• Short bulk melting time
• Process data management
• Easy and quick mould change
• Reduced number of format parts
• Possible stick diameters - 6 to 22 mm
• 3 different mould technologies integrated in one machine
  - Push-out moulds (slim line+ lip balm products)
  - Blow-out moulds (regular lipsticks)
  - Silicone moulds

Filling of Fragile Bulks due to:

• Stirring speed automatically adjusted to actual tank volume
• No product hose
• Exhaust systems
• High end temperature control systems
• Condensation systems
• Servo driven twin nozzles dosing pump (dosing volume adjustable from 2-8 ml) located directly underneath the tank (distance tank /dosing pump<150 mm).
• Complete filling area covered, humidity controlled.

Reliability from the first day:

• High output: 3.000 – 3.600 pcs/hour
• Supply of complete lines: filling - component feeding - assembly - glazing - labelling - sleeving - coding - inspection - winding down – capping
• Easy to operate
• Improved energy consumption
• Strong construction, minimal service necessary
• Best services are guaranteed by skilled technicians - by teleservice.

Tube Filling Machines

Tube Filling Machine
HTF 300
- Output: Up to 20.000 Pcs/H
- Operators: 1-2 persons
- Product: Pharmaceuticals, Toothpaste, Crème, Food (Mustard)

Lipstick Filling Machines
MM060, MM180
- Output: Up to 3.600 Pcs/ H
- Operator’s: 1-2 persons
- Product: any

Lip Balm Filling Machines
MM180; Unifill600
- Output: Up to 36.000 Pcs/ H
- Operator’s 1-2 persons
- Product: Any

Pencil Filling Machines
W060/15 MI, W120 MI
- Output: Up to 6.000 pcs/ h
- Operator’s: 1-2 persons
- Product: Retractable plastic pencils

Deodorant Stick Filling Machine
Unifill
- Output: 7.200 pcs/ h
- Operators: 1-2 persons
- Product: Powder, Gel

Glue Stick Filling Machines
Unifill
- Output: Up to 12.000 pcs/ h
- Operators: 1-2 persons
- Product: Non toxic adhesive

Multipurpose Filling Machines such as Hotfill Filling Machine
For Compacts, Mascara, Lipgloss
- Output: Up to 3.600 pcs/ h
- Operators: 1-2 persons
- Product: Hot and cold poured formulations

Filling Machines

Multi Mould 060

It is a Lipstick filling machinery. This machinery guarantees flexibility and a great variety of stick shapes. It consists of push-out – blow-out – rubber moulds all on one machine. Its output capability is 600 Sticks/h.

The Multi Mould 060 Lipstick filling machine consists of:

• Frame
• Moulding table

The machine is equipped with a stepwisely turning 2-track moulding table with 180 interchangeable blow-out moulds (shape to customer’s design; bullet diameter 3..20 mm). The moulding table has 30 independent hollow chambers, holding 6 moulds each. These chambers are filled with heated or cooled water being in circulation.

The machine can be equipped with:

• Push-out moulds (sl) (metallic mould)
• Blow-out moulds (CL) (metallic mould)
• Rubber moulds (SI) (silicone mould)
• Back-filling moulds (bf) (metallic mould)

Depending on the position of the chambers during a 360° turn of the table, the temperature controlled water is provided – (heated water from ejection to filling position and cooled or no water between the filling position of the table’s next 90° turn). Between this section and the ejection position the chambers are passed by cooled water. The moulding table is driven by a servomotor. The speed of the table is adjustable.

• Heating and cooling system
  There are two water-circulating systems for heating and cooling the temperatures of the moulding table.
• Post melting system
  The post melting system reduces the shrinking crater on the bottom of the bullet.
• Ejection
• Silicone spray system
• Base infeed unit
• Base discharge unit
• Electric cabinet

Pencil – Liner Filling and Packaging Machine W 060 MI

Output: 1.200 leads/hour
Operators: 1 to 2

Description:

The WECKERLE "W 060 MI" model is designed for the production of mechanical lip / eye liner pencils. There are 15 interchangeable 4-fold mould holders (diameter to customer's specification), which are carried in a rotary table.

During the filling procedure, the moulds are heated by temperature-controlled hot water, then cooled by temperature-controlled chilled water, to solidify the leads before they are ejected into the godets of the liner cases by compressed air.

The cooling water is supplied by a remote chiller unit. The bulk is kept liquid in a melting tank offering the possibility of quick and easy colour change.

The tank is equipped with a stirrer and is easy to clean. The regulated tank heating has an accuracy of +/- 1°C. The servomotor driven dosing pump is adjustable from 1 to 4 ml and is connected to the tank by a heated flexible hose.

The heating of the pump body and the connected hose is also controllable to +/-1°C. The pump, with four nozzles, has a diving movement so that the bulk is metered into the heated moulds as the nozzles move upwards.

The filled containers are manually transferred for capping and labelling.

The New Weckerle Fal Hotfill and Assembly Line

Output: app. 3.600 – 14.400 pcs/hr

The Weckerle Hot Filling Line is designed for utmost flexibility due to its modular machine concept (mechanical and electrical) and its quick colour change. Swirl products can also be filled. Machine stand stills are minimized. The main advantages of this FAL60are its flexibility, modularity and the quick format change. This assembly line can also be used in combination with our lipstick filling machines.

Products:

• Mascara
• Lip gloss
• Lip and eyeliner
• Cream powder

Fillable cases / containers:

• Pans
• Jars
• Boxes
• Tubes
• Deodorant sticks

Functions:

• Infeed
• Filling
• Capping
• Closing
• Cartoning
• Sleeving
• Labelling
• Coding(single colour, multicolour, swirl
• Product, melting dosing system)

Glue Stick Filling Machines – Unifill

Output: 60 to 600 sticks/min
Operators: 1 to 3
(depending on the degree of automation)

Description:

The "Unifill" machine model is a flexible machine concept, which can be adapted to the different volume / stick diameter of our costumers.

Unifill describes a linear track-filling machine for a wide range of products (lip balm sticks, deodorant sticks, make-up sticks and even glue sticks).

The temperature of the filling equipment can be adjusted by +/-1°C. These machines are available from 2-track up to 32-track operation. Our philosophy is to have high output with maximum cycle time. This allows the filling of fragile products.
With our advanced-unscrambling units we can feed empty containers very gently with high speed. The servo motor technology became a standard for Weckerle machines; therefore, the machine can be adapted to new products by only changing parameters, providing simple machine management for the operator.