Objectives

Project main Objectives

  •      Optimization of skin profiling for personalized topical treatment
  •      Development of low-cost and low energy manufacturing processes for customized products
  •      Platform specification and the SuperFlex Manufacturing Reference Model of the modular mini-factory platform
  •      Development of the ICT cloud-based integrated platform
  •      Design and produce the mini-factory unit
  •      Integration of the modular mini-factory platform: factory and the ICT platform
  •      Proof of concept: demonstration of a mini-factory platform

The mini-factory structure will be advantageous over a centralized production due to the following characteristics: variability, specificity, frequency, structuring and similarity. As such, the personalized skincare market is extremely adequate to this concept since by definition it is personalized, i.e. with high degree of variability (different ages, persons, needs) and high degree of specificity (different skin biomarkers and health status). Mini-factory preserves the galenic preparation which is important for personalized products, but it gives added values for galenic work by putting it into a frame of automated industrial and controlled production process. This frame enables traceability, reproducibility of products as well as of standardization and regulation to give high quality and cost reduction personalized product production for topical preparations.

 

The main outputs of the new products manufactured via the mini-factory platform.

SuperFlex will reduce the personalized products cost (< 30%) via: 1) novel low cost manufacturing processes: 1a) phase inversion temperature (PIT) or emulsion inversion point (EIP); 1b) preparation of uniform fluid and highly viscous emulsions/nano-emulsions by high pressure (HP) homogenizer; 2) low stocks due to supply raw materials to the mini -factory unit ‘just in time’; 3) centralized main costs at the mother factory, i.e. marketing, R&D, management, high level IP platform.

The time to market will be further reduced by a factor of 10 to one day due to: 1) vicinity to customer and its requests; 2) seamless flow of information from customers’ orders in real time; 3) production of small quantities; 4) enhanced logistics based on newly developed concepts and tools

 

Reduced environmental impact per produced unit compared to traditional larger factories due to: 1) small production units, 2) novel low energy, green processes (EIP and HP), and use of green raw materials (for products and packaging)

 

Set-up and ramp-up time reduction by at least 30% due to the new modular mini-factory concept which will be based on a general approach of flexible production units with exchangeable modules and standardized hardware interfaces.

Furthermore the ICT cloud based platform will be based on a manufacturing reference model, easy to extend and a Cyber Physical System based on a ‘plug and produce approach’. Thus, the platform will be adaptable to the varying needs easily. This concept will allow simplified extension and exchange of process components for production fast ramp-up.

 

The mini-factory concept for local and flexible production is optimal for SMEs and opens remarkable advantages for the European industry enhancing its competitiveness with the huge American and Japanese skin treatment manufacturers.

 

 

 

 
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