L'Oréal Automatic production unit Home > Projects

Objective

With more than 100 years of experience, L’Oréal is the world leader in the cosmetic industry.

L’Oréal is synonymous of beauty, innovation and scientific excellence. Its mission, throughout its more than 100 years of existence, has always been to make beauty accessible to women and men around the world, offering the best in quality, effectiveness and safety in cosmetics.

As the world leader in the cosmetic industry, its success is the result of a unique portfolio of 36 international brands, a global strong presence, specifically in more than 150 countries and a team of 86,000 employees worldwide and more than 2400 employees in Spain.

The objective of the joint work with L’Oréal is the manufacture, assembly and operation of a new fully automatic production unit for the manufacture of shampoos and creams at the L’Oréal facility in Burgos.

Challenges

If the execution of a project of this size is already a challenge, doing it for a company like L’Oréal, which sets the highest quality standards in the cosmetic sector, it gives us the opportunity to raise our standards accordingly in all stages of the project. It is not just about updating the technology and operation of a production unit, but also about a complex dismantling work, both mechanically and electrically, and a major renovation of the equipment support structure. All this, without affecting production and in full compliance with all health and safety regulations.

Solution

Our mechanical, electrical, IT and automation engineering team has worked together with L’Oréal to validate the design solution and automatic process control.

The project has been performed entirely from design, manufacturing engineering development to installation and start-up. The main works have consisted of:

Summary

  • Reactor

 

  • Smelting vessel

 

  • CIP equipment

 

  • Vacuum system

 

  • Dispatching

 

  • Electric cabinet

Result

The project is executed in compliance with all the established requirements and within the implementation deadlines. Given the satisfaction of L’Oreal with the results of the work, it is counting with Orbita for another project of similar dimensions. Below are some highlights:

 

  • Mechanical engineering: Thanks to the advice of our expert cosmetic engineers, innovative solutions are implemented that improve hygienic aspects, reduce manufacturing time and equipment maintenance. All this is achieved by validating each equipment and element of the installation throughout the basic engineering phase.
  • Control system: We achieved to be the only Spanish engineering company validated for the integration of manufacturing units within the recipe management system (ISTRAC). Over several months we were analysing, preparing the integration and then making simulations so that the transition from the manufacturing unit to full automatic (recipe phase) would be made directly and transparently. This was achieved in record time. Being congratulated by L’Oreal and IS2 (manufacturer and integrator of MES Istrac software), with which a fluid and constructive work channel has been maintained.
  • Reference: On the other hand, the solution proposed by Orbita Ingenieria at visualization and control level exceeds the expectations and is presented to the plant as an example of an automation solution. Being a virtual hardware solution, with SCADA Web client, communication with ISTRAC via OPC and PLC/SCADA programming via TIA Portal V16 and WinCC7.5.
  • Communications and IT Security: After a few months of work, it is marked as a pilot project by the IT department. The aim was to improve the communications infrastructure and cybersecurity of the manufacturing unit. From the great work carried out together, a new communications structure and methodology was obtained that was implemented and put into operation with success. From this moment, it becomes the solution for all the engineering future projects. This commitment to the development of infrastructures, technologies and cybersecurity adapted to the needs of L’Oréal continues, expanding the future in new OPC UA means communication between equipment and a new remote access model to control elements.
  • On-site assembly: All the work of dismantling and modifying structures, which required a high precision, was performed successfully reducing the impact on production to the maximum. Being these some of challenges of the project, working in areas with very little manoeuvring space, which complicated the work.
  • Safety, Quality and Manufacturing Validations: The production unit was subjected to L’Oréal validation to verify that it met the established requirements in each aspect, passing all the tests (electrical safety, vaporisation, agitation and emulsion, cleaning, instrumentation, weighing, etc.) ensuring its performance and quality.
Project video

This video shot together with L’Oréal at its facilities reflects the magnitude of the project design and implementation, as well as the key points in process automation.