Factory setup & machinery
Design the production system before buying the line.
Molcol helps connect portfolio, capacity, process flow, utilities, machinery, quality systems, licensing readiness and commissioning for cosmetic, personal-care, pharmaceutical, hygiene, fragrance and automotive-care operations.
Request a factory assessmentFactory roadmap
A workable factory begins with decisions, not quotations.
The roadmap turns commercial ambition into rooms, flows, utilities, equipment and people.
- 01
Feasibility and capacity
Product mix, batch sizes, shifts, demand scenarios, expansion allowance and target unit economics.
- 02
Process and people flow
Segregated movement of materials, personnel, waste and finished goods with practical hygiene zoning.
- 03
Utilities and clean services
Electrical load, purified water, steam or thermal systems, compressed air, vacuum, chilled water, HVAC and drainage.
- 04
Quality and licensing readiness
Documentation architecture, laboratory scope, traceability, calibration, maintenance and market-specific readiness planning.
- 05
Machinery specification
User-requirement specifications based on formula rheology, container, output, cleanability, automation and changeover.
- 06
Commissioning and training
Installation checks, utilities, dry and wet trials, acceptance testing, SOPs, spares and operator training.
Process equipment
Core machinery for liquids, emulsions, fragrance and chemical care.
The exact train changes by formula, viscosity, batch size and hygiene risk.
- 01
Purified-water system
Pretreatment, reverse osmosis, storage and hygienic distribution sized to formulation and cleaning demand.
- 02
Stainless process and storage tanks
Jacketed or atmospheric vessels with suitable agitation, load cells, spray devices and hygienic transfer.
- 03
Vacuum emulsifying homogenizer
Heating, cooling, vacuum deaeration and high-shear emulsification for creams, lotions, gels and toothpaste-type products.
- 04
High-shear and inline mixing
Powder induction, dispersion and recirculation for detergents, shampoos, gels and difficult-to-wet ingredients.
- 05
Reactors and heated mixers
Controlled-temperature processing for selected chemical-care, wax, balm and specialty formulations.
- 06
Perfume chilling and filtration
Maceration tanks, chillers, filter housings and transfer systems for clear fragrance and body-spray production.
- 07
CIP and mobile cleaning systems
Repeatable cleaning of tanks, lines and fillers, supported by defined chemistry, time, temperature and verification.
- 08
Pumps, piping and transfer
Sanitary or chemical-duty pumps, manifolds, hoses and valves selected for viscosity, compatibility and cleanability.
Filling, packaging and end of line
Match the package to the product and the line.
Filling accuracy and pack quality depend on viscosity, foaming, container geometry, closure and required speed.
- 01
Container unscrambler and cleaning
Orient bottles or jars and remove loose contamination before filling where the pack requires it.
- 02
Liquid and paste fillers
Gravity, flow-meter, peristaltic or piston systems selected for thin liquids, foaming products, creams and pastes.
- 03
Tube filling and sealing
Dose creams, gels or toothpaste into plastic, laminate or metal tubes with appropriate sealing and coding.
- 04
Perfume vacuum filling and crimping
Level filling, pump placement, collar crimping and leak-aware handling for fragrance bottles.
- 05
Capping and induction sealing
Cap placement, torque control, pumps, triggers, plugs and foil induction seals matched to the closure system.
- 06
Labeling, coding and vision
Pressure-sensitive or sleeve labeling, date and lot coding, barcode and camera inspection.
- 07
Checkweighing and leak testing
Detect underfill, overfill and selected closure or package-integrity problems before cartoning.
- 08
Cartoning and case packing
Leaflet insertion, cartons, tamper evidence, shrink wrapping, case sealing and pallet preparation.
Pharmaceutical solids
Equipment trains for tablets and capsules.
Solid-dose projects require GMP-oriented containment, dust control, validation and product-specific engineering.
- 01
Sifting, milling and dispensing
Controlled material preparation, de-lumping, particle-size management and weighed dispensing.
- 02
Rapid mixer granulator
Closed high-shear wet mixing and granulation for repeatable binder distribution and granule formation.
- 03
Fluid-bed processor
Drying, granulation or coating with controlled air handling and product-specific spray configuration.
- 04
Blending and handling
Bin, V or double-cone blending with suitable lifting, transfer and containment arrangements.
- 05
Rotary tablet press
Compression with tooling, weight control, dedusting and metal detection selected for formulation and output.
- 06
Tablet coating system
Perforated coating pan, solution preparation and conditioned air for film or selected specialty coatings.
- 07
Capsule filling
Semi-automatic or automatic hard-capsule dosing for powder, granules, pellets or approved combinations.
- 08
Blister or bottle packaging
Blister forming and sealing, or counting, desiccant, capping, induction sealing and labeling for bottles.
Quality, utilities and environmental control
The systems that make machinery usable.
Production equipment cannot compensate for weak utilities, laboratories or maintenance systems.
- 01
HVAC and clean-area control
Pressure cascades, filtration, temperature, humidity and air-change strategy appropriate to process risk.
- 02
Laboratory instruments
Balances, pH, viscosity, density, moisture, UV-Vis, HPLC or GC capability selected by product and specification.
- 03
Stability and microbiology
Controlled chambers, sample management and appropriately designed microbiological testing areas or qualified external routes.
- 04
Compressed air, vacuum and cooling
Dry air, vacuum, chilled water and thermal utilities sized for simultaneous realistic loads.
- 05
Dust, solvent and fire safety
Local extraction, grounding, zoning and protection engineered for powders, alcohol and other process hazards.
- 06
Wastewater and waste handling
Segregation, neutralization or treatment strategies based on actual cleaning and process waste streams.
Equipment selection must follow the approved product portfolio, required capacity, local regulation, utility conditions and validated process. Final engineering and licensing remain subject to qualified local professionals and authorities.