The Challenge

A globally recognized cosmetic brand was facing daily operational challenges in packaging its high-viscosity facial creams. With a viscosity of 10,000 CPS (similar to sour cream or jam), the product consistently pushed conventional IBC liners and filling processes to their limits.

Key issues included:

• Operator dependency: Continuous oversight was required to manually wind product through the dispense pump, tying up labor.
• Significant yield loss: Each IBC left behind an average of 18 kg of cream — about 2% of every batch. At $25 per kilogram, the waste was both costly and unsustainable.
• Inefficient workflows: Manual intervention slowed filling operations, adding to labor intensity and reducing overall throughput .

For the brand, these were not just minor inefficiencies — they translated into higher costs, wasted product, and processes that strained resources.

The Solution

CDF introduced the Air-Assist® IBC liner system, designed to transform filling into a nearly hands-free process while dramatically improving yield.

• Hands-off operation: The Air-Assist liner inflates automatically once air supply is attached, eliminating the need for continuous operator monitoring.
• Maximized product recovery: Trials showed average residual product of just 6 kg (0.67%) per IBC — compared to 18 kg with their previous liner.
• Stronger ROI: The switch added only $25 per liner compared to the old system but unlocked significant savings per batch .

The Results

The Air-Assist® design delivered immediate measurable impact:

• High yield: Up to 99.5% product recovery, cutting residue loss by two-thirds.
• Labor efficiency: Freed operators from constant monitoring, allowing them to focus on other critical tasks.
• Financial savings: 12 kg saved per IBC — worth $300 per batch. With 300 IBCs per month, that translated to more than $90,000 in monthly savings for an incremental investment of only $7,500.
• Scalability: The savings model held true across every batch, providing predictable, ongoing ROI.