Leading-Edge Technology

At Surefil, we apply leading-edge technology throughout our entire operation, including world class compounding, filling and packaging equipment. We specifically designed our manufacturing facilities for hair, skin and oral care filling. The facility has epoxy coated floors in all compounding, pre-weigh and packaging areas. The manufacturing equipment occupies a clean-room area with regularly changed, Hepa-filtered air.

Water

Our plant is equipped with two world-class water purifications systems. By beginning with highly-purified water -- virtually pure water molecules -- which meets the USP 29 standard, we ensure virtually flawless compounding of your product. We also have the ability to control water temperature to a specified degree as it reaches our compounding system.

Each system softens city water, filters the water using carbon, and incorporates both a GE Osmonics reverse osmosis system and a Surefil-designed Electrolytic Deionization (EDI) system. Our systems process 80gpm and feature 100 percent stainless steel water loops built to eliminate opportunities for contamination. We store the purified water in a 4,700 gallon tank, where it circulates at a rate of 120 gallons per minute to prevent bacteria growth. The water then passes through a submicron filter and ultraviolet purification before being used in production. In-line Total Organic Carbon (TOC) and conductivity meters ensure the reliability of the systems.

Compounding

Mix tank capacity ranges from small mixers to 5200 gallons. All of our vessels are stainless steel, 316LSS fully jacketed kettles with low-pressure steam for heating to 190 degrees. In addition, the each have sweep wall agitation with center propellers, clean in place sanitization and are on load cells. We also use two hold tanks, up to 10,600 gallons in size, for each of our mix tanks.

The Surefil transfer system is state-of-the-art, using only stainless steel flow panels and hard piping, not outmoded hoses, quickening changeover time and reducing the expenses associated with lengthy changeovers.

We also utilize a touch screen system to operate pumps, transfer products, control CIP systems, scan raw materials and regulate formulas, eliminating the potential for human error in every step of our processes. All of our compounders are highly-skilled and experienced, once again reducing the possibility of error.

Precision Filling

We operate two high-speed, stainless steel filler/cappers capable of filling bottles and jars ranging from 2 oz. to 32 oz. with tottle and puck capability. The Ronchi Exacta-R filler is an 18 head monoblock filler/capper that runs at a speed of 180 bottles per minute. The filler itself is completely enclosed, a unique, Surefil-engineered design. Prior to entering this filler, your bottles are unscrambled by our pharma grade, 100% enclosed New England Bottle Unscrambler. Our second high-speed filler/capper is servo-driven, features 28 fill heads and 12 cap heads, and operates at a speed of 280 bottles per minute.

Packaging

Our conveyor system is constructed of stainless steel and uses height adjustable rails and vacuums to secure products and reduce waste. Equipment for bottle coding and case erecting, packing and sealing, complete both high-speed packaging lines. Your bottles and jars will be perfectly labeled by our high-speed Shorewood Labeler with 7" web width. And we can apply tamper evident bands with our Marburg-500 banding machine with heat tunnel. Finally, your cases are secured with our Wexxar Case Erector and Sealer and RoboPak Pallet Wrappers.

System Integration

To ensure your product is produced to your specifications, Surefil integrates our compounding, filling and packaging systems with Allen Bradley micro logic controls.

Cutting-edge technology for precision filling

At Surefil, we apply cutting-edge technology throughout our entire operation, including world-class filling equipment. Unlike many traditional filling machines, our Ronchi fillers ensure simple, rapid and inexpensive product change. Stainless-steel construction further ensures that your filling requirements - whether viscous or foamy liquids are involved - can be met quickly and easily.

Our equipment offers precise filling accuracy - to within +/- 0.2 percent. Mass flowmeters handle all products and ensure precision dosing in all applications where weight measurement is required. This measuring is highly responsive to the needs of the cosmetic, pharmaceutical, and personal industries.

Ronchi's patented "Quick Set" system releases bottle change parts as a unit directly from the machine operator's control panel, locking new change parts into place for maximum production flexibility when switching from one bottle format to another.

Of course, equipment performance is entirely dependent on thoroughly trained personnel. Surefil cross-trains our technical staff and updates all employee training profiles and protocols on a regular basis.