CHC helped Caudalie build a more controlled product handling process that connects unpacking, automated labeling, inkjet marking, accumulation, repacking, case sealing, and palletizing into one integrated workflow.
Caudalie is a global skincare brand with a product portfolio that requires careful handling, accurate labeling, and consistent presentation through fulfillment and repacking operations. At the company’s Carlstadt, New Jersey facility, Caudalie needed a more organized way to move products through unpacking, labeling, inkjet stamping, accumulation, repacking, case sealing, and palletizing.
For a cosmetics and skincare operation, accuracy is critical. Products may require discount labels, tester labels, SKU replacement labels, lot codes, expiration dates, or other identifying marks before being repacked and prepared for downstream handling. When those steps are handled manually or disconnected across several work areas, the process can become inefficient, inconsistent, and difficult to scale.
The goal was not just to move product from one end of the line to the other. The goal was to create a cleaner, more accurate, and more flexible workflow from unpacking through palletizing.
Caudalie’s process required product to be unpacked from master cartons, case sets, or product packaging before moving through several value-added steps. Each product then needed to be labeled, marked, accumulated, repacked, sealed, and prepared for palletizing.
Without a properly integrated system, this type of operation can create avoidable labor, workflow, and accuracy challenges.
Caudalie needed a system that could organize product flow while remaining flexible enough to support different production volumes, product types, label requirements, and repack configurations.
CHC designed an integrated product handling line that connected each major step of the operation into a coordinated workflow. The system begins at ergonomic unpack stations, where operators remove products from packaging while empty packaging is moved out of the work zone by an overhead gravity takeaway conveyor.
From there, product is placed onto a flighted conveyor that maintains consistent spacing as items pass automated top and side label applicators and an inkjet printer. After labeling and marking, the system moves product to accumulation and repacking areas, then into case sealing and end-of-line palletizing.
Ergonomic unpack stations help reduce reach, lifting, and repetitive motion while keeping packaging and product flow separated.
Flighted conveyors help maintain spacing through the labeling and inkjet sections, supporting more consistent product presentation.
Top and side label applicators, paired with inkjet printing, help support product identification, traceability, and downstream accuracy.
Accumulation tables provide controlled product staging so operators can repack products without disrupting upstream movement.
System operations begin at designated unpack stations, where product is removed from master cartons, case sets, or product packaging. The work area is designed to support ergonomic positioning and reduce unnecessary reach, lifting, and repetitive motion.
Product packaging is transferred from the work zone using an overhead gravity takeaway conveyor, helping keep work areas clear while making packaging available for repack operations.
Once products are unpacked, they are placed on a flighted conveyor and conveyed past top and side labeling applicators and an inkjet printer.
These systems support discount labels, tester labels, SKU replacement labels, lot codes, and expiration dates. The flighted belt helps maintain product spacing to improve label placement accuracy and reduce jams.
After labeling and inkjet stamping, products discharge to accumulation tables that temporarily buffer product flow. This gives operators a structured area to repack products into the correct packaging, cartons, trays, or multi-pack formats.
The accumulation zones help maintain order accuracy, support batch processing, and prevent upstream or downstream stoppages.
After repacking, completed cases are placed onto a gravity conveyor and routed into a customer-supplied semi-automatic case sealer.
The sealed cases then discharge onto a gravity conveyor for palletizing, helping reduce unnecessary handling while keeping the end-of-line process organized and ready for storage or shipment.
CHC’s role extended beyond equipment supply. As the systems integrator, CHC coordinated the mechanical, electrical, controls, installation, startup, commissioning, and operator training required to bring the system together.
| System Area | Equipment / Function | Purpose |
|---|---|---|
| Product Conveying | Product conveyor sections with adjustable guardrails | Move product through the line while maintaining a controlled path through each process step. |
| Product Spacing | Flighted conveyor sections | Maintain consistent product spacing through labeling, inkjet printing, and repacking zones. |
| Packaging Flow | Overhead gravity takeaway conveyor | Move empty packaging away from the operator work zone and support downstream repack activity. |
| Labeling | Top and side print-and-apply label applicators | Apply required product labels, including discount, tester, SKU replacement, and other label formats. |
| Inkjet Marking | In-line inkjet printer | Print variable information such as lot codes, expiration dates, logos, and other product markings. |
| Accumulation | Dual accumulation tables | Temporarily buffer product flow and provide structured storage for repacking operations. |
| End-of-Line Handling | Gravity conveyor and customer-supplied semi-automatic case sealer | Move completed cases through sealing and toward palletizing with reduced manual handling. |
| Controls | Main control panel, PLC, HMI, VFDs, field devices, and system interlocks | Coordinate system operation, operator interface, startup, stopping, safety, and equipment communication. |
CHC’s project team also supported operator training, helping Caudalie’s personnel understand the operating, maintenance, and safety requirements of the system.
The completed system was designed to give Caudalie a more controlled, consistent, and operator-friendly product handling workflow from unpacking through palletizing.
Packaging, product, labeling, repacking, and case handling are organized into a more connected process with fewer disconnected work areas.
Automated label application and inkjet marking help support more consistent product identification, traceability, and downstream processing.
Flighted conveyors and accumulation tables help control product spacing, staging, and transitions between each step of the line.
By connecting each step into one integrated process, the system helps reduce unnecessary manual handling and maintain more consistent product presentation through labeling and marking. The flighted conveyor supports accurate label placement by keeping product spacing controlled, while automated labeling and inkjet printing help reduce manual error and support traceability.
The accumulation and repacking areas give operators structured buffer zones that help prevent stoppages between upstream and downstream processes. At the end of the line, the case sealing and palletizing flow helps move finished cases toward shipment or storage with fewer touches and a cleaner operational path.
Most importantly, the project gives the facility a scalable product handling process that supports multiple product configurations, label types, print requirements, and repack workflows without forcing the operation into a rigid, one-size-fits-all system.
Cosmetics and skincare fulfillment often involves a high number of SKUs, varied packaging formats, strict labeling needs, and frequent product changeovers. In that environment, small handling inefficiencies can multiply quickly.
A product may need a discount label, tester label, SKU replacement label, lot code, expiration date, or other variable marking before it can move forward. If that process relies too heavily on manual handling, operators are forced to manage accuracy, spacing, staging, repacking, and flow control at the same time.
This project shows how the right combination of conveyor, labeling automation, inkjet printing, accumulation, controls, and operator-focused layout can create a cleaner and more reliable workflow.
CHC’s role was to bring those pieces together as one integrated system.
Whether your operation needs product labeling, repacking support, inkjet coding, case handling, conveyor integration, or a more controlled end-of-line workflow, CHC can help design a solution around your facility, product requirements, and operational goals.
From concept and layout through equipment selection, installation, controls, commissioning, and training, CHC provides the integration experience needed to make material handling systems work in the real world.
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