PackSys Global will unveil a fully automated tube head manufacturing process for premium cosmetics tubes at K 2025 in Düsseldorf, showcasing advancements in efficiency, sustainability, and product choice. Presented in collaboration with other Brückner Group companies, the display will highlight how cutting-edge packaging technologies can work together in economically, environmentally, and technologically optimal ways.

At the heart of the stand will be a fully operational Prestige 40 tube head manufacturing process, demonstrating all key stages of compression molding – from unpacking tube heads to shipping-ready packing. The system integrates three core machines into a coordinated process.

The BoxButler begins the sequence, unpacking extruded or laminated tubes from boxes and feeding them gently into the line. The Prestige 40 then attaches the tube head and cap in a single step, offering short setup times and high format flexibility for premium extruded tubes. Finally, the CoreMaster packs finished tubes into boxes automatically, ensuring consistent quality without manual intervention.

Making its debut at the show, the noSho tube is a new sustainable solution processed by the Prestige 40. It eliminates the need for a separate plastic closure, integrating the closure during manufacturing. This approach reduces material use by up to 80%, streamlines production, and lowers the environmental footprint while maintaining design, functionality, and recyclability.

Also on display will be the LineButler, an end-of-line solution that automates all packaging steps – from carton forming to palletizing – reducing operator workload and personnel needs while ensuring stable, high-quality results. Its modular design allows customization for space, process, and ergonomic requirements.

In service innovations, the smartcube digital platform will be presented as a central hub for spare parts management, training, and operational data, enhancing transparency and optimizing machine performance. Retrofit solutions will also be highlighted for upgrading existing systems with new functions or components.

For quality assurance, PackSys Global will showcase the capLAB, an intelligent system for automated cap inspection. It measures parameters such as pull-off strength, tightness, geometry, and cleanliness in real time, providing complete documentation to maintain high product quality and reduce scrap.