Case Study: Doubling Spray Pump Production with Fully Automatic Assembly Lines
Industry: Medical & Cosmetic Spray Pump Manufacturing
Solution: Gereke Automatic Spray Pump Assembly Machines
Customer Background
A mid-sized manufacturer of nasal spray pumps, lotion pumps, trigger sprayers and perfume spray nozzles, supplying pharmaceutical and personal care brands across Europe and North America, was facing a familiar bottleneck: manual assembly could only reach 15 to 20 pieces per minute. Defect rates fluctuated around three percent, labor costs were rising, and seasonal orders could not be fulfilled on time.
The Challenge
- Low output: manual lines limited to 15-20 pcs/min
- Inconsistent quality: gasket fitting and dip tube insertion errors
- High labor dependency: 12 workers per shift
- No in-line inspection or leakage testing
- Frequent changeovers between nasal spray, lotion pump and trigger sprayer products
The Solution
Gereke Machinery deployed a fully automatic spray pump assembly line combining a sprayer head automatic assembly machine, a pump core assembly and inspection machine, and an oral spray filling machine with aluminum tube and sprayer cap crimping. The complete line was designed around high-performance PLC control with touch screen and inverter, electronic cam transmission, and vibrating bowl feeders for stable, continuous component supply.
Key machines installed at the customer plant:
- Spray Head Full Automatic Assembly Machine (2 Up design) - assembles sprayer heads with precision at high speed
- Nasal Spray Pump Automatic Assembly Machinery - 3,600 pcs per hour for gasket fitting and dip tube insertion
- Aluminum Bottle Sprayer Cap Crimp Automatic Assembly Machine - for medical oral spray filling applications
- Sprayer Pump Core Automatic Assembly and Inspection Machine - combines assembly with in-line quality inspection
- Sprayer Pump Engine Automatic Assembly and Leakage Test Machine - verifies pump integrity before packaging
Machine Specification Highlights
| Parameter | Value |
|---|---|
| Operating speed | 60-80 pcs/min (up to 3,600 pcs/hour) |
| Control system | PLC with touch screen and inverter |
| Transmission | High-performance electronic cam |
| Feeding system | Vibrating bowl feeder |
| Construction material | Stainless steel / S45C steel |
| Applicable products | Nasal spray, lotion pump, trigger sprayer, perfume nozzle, oral spray |
| Certification | CE, ISO9001 |
The Results
- Output increased from 20 to 80 pcs/min, a four-fold capacity improvement
- Defect rate reduced to below 0.5 percent through integrated inspection and leakage testing
- Labor reduced from 12 to 2 operators per shift
- 24/7 continuous production capability with stable electronic cam transmission
- Quick changeover between nasal spray pumps and trigger sprayer products
Why Gereke Machinery
With 19 years of experience in designing and manufacturing assembly, filling and labeling machines, Gereke Machinery focuses on medical, cosmetic and writing instrument machinery, offering fully automated production lines with CE certification. Every machine is built with international brand components, including PLC, sensors, cylinders and inverters from Japan, Korea, Taiwan and Europe, ensuring low failure rates and long service life.
The customer now runs three automated spray pump lines with a combined capacity of more than 10,000 pieces per hour, and has expanded into new markets including aerosol spray assembly and medical oral spray filling.
Conclusion
If your factory still relies on manual spray pump assembly, Gereke automatic spray pump assembly machines can help you cut labor costs, improve quality consistency and scale up production. Contact Gereke Machinery today for a customized assembly line solution tailored to your product range.