Decoplas™ 120 line
Efficient production of premium cosmetic tubes with functional and versatile components at 120 tubes per minute
Built on Aisa’s proven Decoplas™ extrusion labelling and Saesa® component assembly technologies, the Decoplas™ 120 Line offers a highly versatile solution for producing extruded cosmetic tubes with premium label quality decoration and sophisticated pre-moulded shoulder and cap assemblies, including complex formats such as shoulder-less tubes.
Covering a large range of tube formats, from small Ø19 mm to big Ø60 mm, including oval shape, the Decoplas™ 120 Line is ideal for tube producers seeking maximum decoration flexibility, consistent quality, and recyclable tube manufacturing capabilities.
As an alternative to a direct printing line, the Decoplas™ technology removes the need for in-line printing and enables on-the-fly decoration changes without interrupting production, significantly reducing downtime and improving overall productivity. At the heart of the KSM system, Aisa’s Saesa® technology sets new standards in tube manufacturing by seamlessly assembling sleeves with pre-injected shoulders and caps. This advanced process eliminates mould cooling-time impact on productivity, ensuring consistently efficient production.
Line configuration
From right to left, the complete line includes:
- DXL 120 sleeve extrusion and labelling unit
- Transfer and accumulator
- KSM 120 header and capper using Saesa® technology
Key benefits
Productivity & Efficiency
- Lower investment as one offline printing can supply up to 4 Decoplas™ 120 Lines
- Optimisation of printing costs thanks to flat printing ability to handle several artwork on the same width
- High productivity through fast decoration changeovers without production interruption
- Improved performance thanks to Saesa® assembly, which eliminates cooling delays
- Compact design with reduced floorspace requirements
Decoration Capabilities
- 360° end to end highly decorated sleeve
- Supports flexography, silkscreen, digital, cold foil — in combination
- Premium visual quality superior to direct round printing
Sustainability & Materials
- Produces tubes compatible with the HDPE coloured bottle recycling stream
- Capable of using 100% extrusion-grade PCR materials
- Best solution for the production of cosmetic tubes with functional heads, such as shoulder-less or one-piece pumps, which are challenging to produce with compression moulding
Quality & Integration
- Fully integrated automated quality inspection systems
- Orientation systems for perfect finish
- End-to-end Aisa-made solution
- Ready for seamless integration with packing machine
Machine specifications
Machine capabilities
Up to 120 tubes/min.
Tube Ø13.5 mm to 60 mm
Sleeve length 60 to 235 mm
Sleeve extrusion speed up to 24 m/min.
Value-adding options
Safety seal applicator
Snap-on and screw-on cap alignment to artwork
Oval tube production capability
Production Data Interface to MES
Interface for packing machine integration
KSM Quality Control Systems
Smart Shoulder Orientation control
Smart Cap Orientation control
Vision systems for quality control