What container types and fill sizes can ALFA MFG accommodate?

Our 17 production lines handle sizes from 5 ml unit-dose sachets and 10 ml glass dropper vials up to 32 oz retail bottles and 128 oz (1-gallon) bulk backbar jugs. Packaging formats include round, oblong, and square bottles, double-wall jars, plastic and laminate squeeze tubes (30mm to 50mm diameter), and multi-layer sample sachets.

What are your filling tolerances and quality standards?

All operations follow ISO 22716 cGMP protocols and U.S. FDA MoCRA guidelines. We maintain tight volumetric and level-fill tolerances with in-line checkweighers, torque monitoring, seal integrity testing, and vision-verified lot code tracking.

What secondary packaging and finishing options are available?

In-house finishing capabilities include high-speed wrap and front/back pressure-sensitive labeling, full-body shrink sleeving with dual steam tunnels, radiant heat tamper-evident neck banding, induction cap sealing, high-contrast inkjet coding (including yellow ink for dark bottles), carton folding, and master case display assembly.

Cosmetic Filling & Labeling Services | 17 Automated Lines

Line Specifications

Engineered Filling for Every Primary Format

Whether launching a specialized boutique run or scaling high-volume national retail inventory, our cleanroom-grade liquid and viscous filling lines maintain strict fill accuracy, seal reliability, and hygienic integrity.

High-volume multi-piston overflow filling line

High-Velocity Operations

Multi-Piston & Rotary Overflow Lines

Designed for cosmetic liquids, shampoos, lotions, and conditioners requiring cosmetic fill-level consistency across transparent or semi-translucent retail packaging.

20-Piston Overflow Line: 1 oz – 32 oz containers | Operating speeds 40 – 60 BPM
12-Piston Overflow Line: 1 oz – 32 oz containers | Operating speeds 24 – 48 BPM
8-Piston Volumetric Line: 1 oz – 32 oz containers | Operating speeds 16 – 32 BPM

Automated Capping In-Line Torque Inspection Continuous Conveyance

Versatile low-volume and hot-fill piston machinery

Agile Batch Operations

Semi-Automated & Hot-Fill Piston Systems

Optimized for high-viscosity balms, hair pomades, body butters, and pilot batches where product viscosity necessitates heated delivery or frequent tooling changeovers.

Single Piston Hot-Fill: 0.5 oz – 10 oz | 6 – 10 BPM with jacketed hopper heating
Single Piston Fluid Line: 1.7 oz – 17 oz and 3.4 oz – 34 oz range | 6 – 10 BPM
Bulk Gallon Station: 64 oz – 128 oz (1 Gallon) salon backbar fills | 6 BPM
Mini 4-Piston Volumetric: 0.5 oz – 8 oz jars and squeeze bottles | 12 – 20 BPM

Hot Pour Capability Viscous Emulsions Gallon Jugs

Automatic cosmetic tube filling and sealing machine

Extrusion Formats

Rotary Automatic Squeeze Tube Fillers

Precision ultrasonic and hot-air sealers for plastic, polyfoil, and aluminum laminate tubes, ensuring crisp hermetic crimps, clean orientation, and batch embossed coding.

9-Puck Automatic Tube Filler: 1 oz – 8 oz volume capacity | 30 BPM
Tooling Diameter Range: Ø 30mm, 35mm, 40mm, 45mm, and 50mm collars
Single-Puck Specialty Filler: 0.5 oz – 8 oz pilot or specialty runs | 6 BPM
Closure Capabilities: Flip-top, screw cap, needle-nose nozzle, tamper-seal foil

Hot-Air Sealing Embossed Lot Coding Trim & Clean Crimp

Peristaltic monobloc filler for glass serum vials and droppers

Precision Dosing

Glass Vials, Droppers & Monobloc Systems

Zero-shear peristaltic pumping designed specifically for active facial serums, facial oils, essences, and fragile skincare actives with pharmaceutical-grade volume repeatabilities.

2-Pump Matrix Peristaltic: 10 ml – 4 oz glass containers | 12 – 20 BPM
4-Pump Peristaltic Filler: 0.5 oz – 8 oz bottles and vials | 16 – 24 BPM
2-Pump Monobloc Filler: 10 ml – 2 oz luxury dropper packaging | 30 BPM
12-Pump High-Speed Monobloc: 1 oz – 4 oz with auto-feeder & auto-capper | 60 BPM

Dropper Inserter Non-Contact Peristaltic Nitrogen Purge Compatible

Finishing & Secondary Packaging

Labeled, Sleeved & Retail Shelf-Ready

Cosmetic manufacturing excellence depends as much on outer package presentation as formula stability. Our integrated finishing departments eliminate secondary handler logistics, reducing transit risk and lead times.

Automated Labeling

Equipped with 4x automated wrap-around labeling units for cylindrical jars and bottles, plus precision front-and-back labeling machines for oval, square, and flat containers. Dedicated rotary tube labeling accommodates flexible packaging without air-pocket distortion.

Steam & Radiant Heat Sleeving

Full-body graphic shrink sleeving executed through dual steam tunnels ensuring zero blister defects on contoured bottles. Three radiant heat tunnels manage transparent neck banding, tamper-evident seals, vertical/horizontal micro-perforations, and multi-unit bundled retail sets.

Unit-Dose Sachet Packaging

Horizontal and vertical Form-Fill-Seal (FFS) sachet machinery for promotional sampling, hotel amenities, and single-dose retail treatments. Tooling supports rectangular dies (5 ml to 10 ml), 15 ml rectangular sachets, and square die geometries with clean tear notches.

Coding & Tamper Verification

High-resolution continuous inkjet (CIJ) coding including black ink and pigment-rich yellow ink engineered for legibility on dark glass and amber plastics. Includes automatic induction cap sealing, tamper seals, and vision inspection.

Silk Screen Coordination

For prestige brands seeking direct-to-bottle printing, our engineering department coordinates decorative silk screening, UV varnishing, and hot-stamp foil printing with accredited domestic and international packaging partners.

Display Assembly & Packouts

Complete turnkey fulfillment capabilities: folding cartons, multi-piece starter kits, promotional sleeves, corrugated Point-of-Purchase (POP) displayers, inner carton partitions, and palletization to major retailer routing specifications.

Quality Governance

cGMP Standards Built into Every Production Hour

Our Miami facility operates under rigorous ISO 22716 certification audited by SGS. Standard operating procedures safeguard batch identity, container sanitation, fill integrity, and strict adherence to U.S. and overseas regulatory mandates.

SGS Audited ISO 22716

Documented line clearances, sanitized fluid pathways, HEPA air filtration zones, and complete batch production records (BPR) preserved for full traceability.

100%Lot Traceability

Statistical Weight Control

Periodic in-process gravimetric sampling and in-line checkweighers guarantee every unit meets declared net contents under U.S. NIST Handbook 133 standards.

±0.5%Dosing Repeatability

Seal & Torque Verification

Calibrated digital torque testers verify closure seals against leak benchmarks, while vacuum chamber testing confirms induction and tube crimp strength under altitude variations.

ASTMLeak Testing Protocols

Global Compliance Ready

MoCRA facility registration, full cGMP Certificate of Analysis (CoA) documentation, tamper-evident seals, and barcoded pallet shipping compliance for global customs clearance.

FDAMoCRA Compliant

Procurement FAQ

Frequently Asked Production Questions

Key technical specifications and minimum parameters procurement teams evaluate during vendor qualification.

What are the minimum order quantities (MOQs) for filling and labeling runs?

Production minimums correspond to container typology and tooling setup: 10,000 units for liquid sachets (5–15 ml); 5,000 units for standard bottles, jars, and vials (reduced to 2,500 units for luxury high-potency skincare); 2,500 units for standard squeeze tubes and 2.1 oz to 32 oz containers; and 480 units for 128 oz salon backbar gallons.

Can ALFA MFG fill packaging supplied directly by the client?

Yes. Under our contract packaging framework, clients may provide components (bottles, pumps, jars, tubes, caps, and pre-printed labels) directly. Our engineering team conducts component compatibility and puck alignment trials prior to scheduled batch execution.

How do you prevent cross-contamination during product switchovers?

All lines utilize validated Clean-in-Place (CIP) and dedicated sanitary stainless steel (316L) food-and-cosmetic grade contact components or single-use peristaltic silicone tubing. ATP swab testing and microbiological validation are conducted between every batch changeover.

What secondary packaging assembly options can you handle in-house?

Our packout lines manage bottle and jar cartoning, insertion of package leaflets, heat-shrink bundling for promotional multi-packs, retail shelf-ready master shipper packing, and barcoded palletization according to retailer routing guides (Target, Ulta, Sephora, Amazon FBA, CVS).

Cosmetic Filling Lines — Bottles, Jars, Tubes & Sachets