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Lotion line runs smoothly with new monobloc machinery

New monobloc filler/capper with unique bottle-feeding system produces 90+ bottles of lotion/min.

OPI Products, Inc., North Hollywood, CA, is one of the world’s largest producers of manicure and pedicure products, with 2,500+ skus sold throughout the U.S. and in 100 countries around the world. To keep pace with growth, OPI invests approximately $1 million each year in packaging equipment.

In January 2007, OPI installed the model FC42 filler/capper from Capmatic Ltd. ( to accommodate increased production of its line of lotions in 1-oz oval, tapered bottles.

Because of the light weight of the 1-oz bottles, a special system feeds them to the filler. It  begins with a bulk feed hopper, which is supplied manually with the 1-oz bottles by the operator. From there, bottles are carried upward by a bulk feed elevator to a custom Capmatic rotary unscrambler. Within the unscrambler, bottles are oriented onto a flat, horizontal conveyor that then splits into two chutes. The chutes carry the bottles single-file down toward the monobloc filler/capper and drop them two at a time into an indexing wheel, just prior to the filling station.

Once fed to the monobloc, bottles are indexed two at a time to the filling station, then the capper, and then the cap torque station. The Intrepid is equipped with an Allen-Bradley PLC from Rockwell Automation ( and Festo ( pneumatics. To feed caps to the monobloc, Capmatic supplied a 4-cu-ft hopper that uses a bulk feed elevator to carry caps to a vibratory bowl.

After bottles are discharged from the monobloc, they are carried by conveyor into a starwheel. Positioned underneath is an A200 small-character ink-jet printer from Domino Amjet ( that places a batch code on the bottom of each bottle as they pass overhead. Bottles then proceed downstream to be labeled simultaneously on front and back by a Capmatic LabelStar System 2/2 pressure-sensitive labeler.

Labeled bottles exit the conveyor onto an accumulation table, from which two operators pick product and pack it into trays.

To read the article that accompanies this video, see Two new lines handle manicure, pedicure products with ease. To view a second video, detailing OPI’s new tube-filling line, see OPI Products puts best foot forward with new Norden tube-filling line.

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