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Unilever Dubai meets end-of-line challenges with automation

The largest personal care plant in the Middle East-Africa, Unilever Dubai handles product collation, shrink bundling, case packing, and palletizing of eight shaped bottle sizes at 350/min, with a 10-min changeover.

Eight bottle sizes are packed on each of the two lines.
Eight bottle sizes are packed on each of the two lines.

The Middle East-African market has become a target for billions of dollars of investment by those global Consumer Packaged Goods companies in the beauty and personal care space looking for growth opportunities. According to market research firm Euromonitor, over the next five years, this area is expected to be the fastest-growing region in the world for such products, due to young populations and rising levels of spending in many Middle East-African countries.

In December 2016, Paul Polman, CEO of Unilever, inaugurated the company’s $250 million Dubai Personal Care (DPC) manufacturing facility in Dubai Industrial Park, United Arab Emirates. The largest personal care liquids manufacturing plant in the Middle East-North Africa (MENA), the plant spans approximately 328,000 sq ft and is equipped with “state-of-the-art technology which, combined with a modular design, ensures faster, shorter, and highly responsive production lines that cut lead time to market by 80 percent,” according to Unilever. “The lines are additionally highly flexible to match market demand, while delivering the highest levels of product quality and safety,” the company adds.

Acknowledging that the UAE is a strong trade corridor that connects the East and West with significant growth potential and a world-class infrastructure, Unilever has chosen the slogan “Made in the UAE” for its DPC products. Produced and packaged at the plant are haircare and skincare brands that include Dove, Fair & Lovely, Lifebuoy, Vaseline, Clear, TRESemme, and Sunsilk. Each year, the Dubai plant produces 500 million items, or 100,000 tons of liquid product.

In equipping two bottling lines for its shampoo and conditioner products in shaped bottles, Unilever looked to Gebo Cermex for end-of-line machinery for product collation, shrink bundling, case packing, and palletizing. Gebo Cermex was chosen for its engineering and robotics expertise as well as its ability to combine and customize existing solutions to meet Unilever’s individual specifications.

Given the complexity of the project, Gebo Cermex faced some challenges in meeting Unilever’s expectations for the equipment. The machinery needed to handle shaped containers in eight sizes, from 100 to 900 mL, at speeds to 350 bottles/min, while achieving a maximum 10-min line changeover with multiple changeovers per day. Says Jean-Philippe Beduneau, Strategic Key Account Director for Unilever at Gebo Cermex, “We have a unique capability to propose complete end-of-line solutions for unstable bottles or bottles with complex shapes that do not allow for mass flow accumulation. …Our existing portfolio is able to respect the specifications typically linked to shaped, unstable bottles. Nevertheless, in the Unilever case, their expectations about line speed and maximum time for changeovers challenged our design department to stretch the boundaries of the current range and merge modules and technologies like we never have before.”

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