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Weleda skin food products in front of a blurred nature background.

Weleda – Sustainable cosmetics production with IWK technology.

Energy-efficient tube filling and cartoning line for natural cosmetics – precise, flexible and fully validated.

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Smart Engineering for Natural Cosmetics

Aligning sustainability with efficiency.

As a pioneer in natural cosmetics, Weleda placed high demands on a new packaging line: sustainable materials, hygienic filling processes, a wide variety of formats and maximum energy efficiency. At the same time, the line had to reflect increasing production volumes and quality requirements – with clearly defined validation and sustainability targets.

Green folding cartons on a curved conveyor belt in a production line.

Smart engineering for sustainable cosmetics production.

IWK developed a tailor-made tube filling and cartoning line that combines sustainability, efficiency and process reliability.

The core of the solution is an energy-optimized machine concept with servo-controlled movement axes, CIP / WIP cleaning systems and modular line integration. The plant processes recyclable tubes and paper-based secondary packaging – a central element of Weleda’s sustainability strategy.

Technical features:

  • Validated filling according to GMP and GAMP 5
  • Variety of formats: different tube materials and sizes
  • Automated transfer to cartoners with quality control
  • Energy-efficient servo drives and smart motion profiles
  • Line integration with central control and digital monitoring
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Weleda tubes in an automated packaging system with sensors and mechanical guide elements.
Sustainability & Safety 

Efficiency meets sustainability.

The new packaging line enables Weleda to:

  • Energy savings through optimized motion sequences
  • Reduced changeover times due to tool-free format changeovers
  • Validated processes with full traceability
  • Sustainable packaging thanks to pacblue-compatible materials
  • Higher line availability with constant quality

The combination of precision, flexibility and sustainability strengthens Weleda’s position as an industry pioneer in environmentally conscious cosmetics production.

Weleda AG
Project Management Packaging Technology
With IWK, we have found a partner who combines sustainability and technical precision. The new line is an important step in our strategy for resource-saving, GMP-compliant production.

Technical highlights of the Weleda line

Machine Types
IWK Tube Filler FP Series, IWK Cartoner SC Series
Performance
up to 220 tubes per minute
Materials
Metal, plastic, laminate and recycled tubes, paper-based cardboard packaging
Standards
GMP, GAMP 5, EU Annex 15
Features
CIP / WIP, Track & Trace, patented cycloidal system for process-reliable folding carton erection
API settings
MES, ERP, digital line monitoring

Frequently asked questions about the Weleda project

Energy consumption per pack has been reduced, and only recyclable packaging materials are used.

Yes, the line has been designed, documented and validated according to GMP and GAMP 5.

Yes, the concept is modularly scalable and can be adapted to product and material requirements.

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Jennifer Steinhausen-Hanspach
Team Leader Sales Administration
jsteinhausen@iwk.de

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