How to expand production lines in the food, cosmetics and chemical industries

4-step guide to scale up production lines in the food, cosmetics or chemical industry without losing control.

In demanding sectors such as food, cosmetics and chemicals, growth cannot be improvised. Increasing production capacity not only means adding machinery or extending shifts, but also strategically redesigning processes, flows, validations and regulatory structures to ensure operational continuity, quality and legal compliance.

This article offers a practical protocol in 4 steps to guide the expansion of production lines in food, chemical or cosmetic industries. With a practical approach, the result of MarCoPack’s experience, and adapted to current technical and regulatory realities, it will allow you to scale up your production in a safe, profitable and sustainable way.

Step 1: Identification of needs, market and regulatory requirements

Before investing in machinery, automation or redesigning your plant, you need to answer a key question: What are you trying to solve or improve?

This first step makes the difference between a successful scale-up and a constant source of inefficiencies, bottlenecks and compliance problems.

1.1. Market study and strategic objectives

• Growing demand: Is your current production no longer meeting actual or projected demand?
• New products or formats: In cosmetics, they may involve changes in viscosity, materials, labeling or handling. In chemistry, the introduction of new formulations may require separate reactors, tanks or lines.
• Efficiency and competitiveness: Increasing capacity does not always mean “more of the same”; sometimes it means faster, safer or more flexible processes.

Example: A natural cosmetics company incorporating a new line of serums must consider not only capacity, but also material compatibility, dosing accuracy and GMP (Good Manufacturing Practices) compliance.

1.2. Analysis of current production capacity

• Evaluate the real situation of your lines: Where are the bottlenecks? What is the cycle time of each process?
• Useful tools:
  • OEE (Overall Equipment Effectiveness)
  • Time and motion studies
  • Simulations using digital twins
  • Value Stream Mapping (VSM)

MarCoPack recommends relying on actual data from the MES or ERP system to accurately establish this baseline.

1.3. Regulatory and quality requirements by sector

Each industry has specific regulatory requirements that condition the way to scale:

• Food Industry:
  • Regulations and certifications: HACCP, IFS, BRC, halal, vegan, vegetarian,….
  • Implications: separation of dirty/clean areas, food materials, full traceability, critical point control.
• Cosmetic Industry:
  • Standards and certifications: ISO 22716, Regulation (EC) 1223/2009.
  • Implications: cleaning validation, process documentation, cross-contamination control.
• Chemical Industry:
  • Standards and certifications: REACH, CLP, ADR
  • Implications: ATEX zones, waste management, dust or vapor containment, safety control and labeling.

Anticipating regulations avoids redesigns or adjustments later on. Collaboration with packaging and industrial machinery specialists like MarCoPack will facilitate integration from the start.

Result of Step 1

At the end of this step you should have:

• A technical report with the specific needs for expansion.
• An analysis of current and future capacity.
• A mapping of critical regulatory requirements by product and process.
• An objective and documented basis for moving on to the technical design of the expansion.

Step 2: Design, simulation and adaptation of infrastructures and processes

Once the regulatory needs and constraints have been defined, the next step is to convert those requirements into concrete plant, machinery and technology solutions. This is where the technical, economic and operational feasibility of the expansion is defined.

This step includes three key components: layout design, equipment selection and pre-validation through simulation.

2.1. Industrial layout design and production flow planning

An inadequate plant layout can cause an expansion to fail, even if the best machinery has been chosen. That is why the layout must:

• Optimize routes, minimize transfers and avoid cross-contamination.
• Enable unidirectional flows in the food and cosmetics industry.
• Include differentiated areas: preparation, production, washing, storage, personnel, quality control, etc.
• Be scalable: think of future modules to avoid costly redesigns.

Sectoral examples:

• Food: including airlocks, cold zones, chambers and CIP washing systems.
• Cosmetic: areas with controlled flow of people, high pressure sinks, clean rooms (GMP).
• Chemical: ATEX spaces, containment areas, safe storage of flammable or toxic raw materials.

MarCoPack Tip: incorporating Lean Manufacturing criteria from the design stage can reduce production times and losses due to unnecessary movements by up to 25%.

2.2. Selection of machinery and adapted automation

The choice of equipment should be aligned with:

• Product properties (viscosity, particle size, temperature, corrosiveness).
• Packaging characteristics (material, shape, volume).
• Current and projected production volumes.

Key elements:

• Dosing and packaging machines compatible with delicate, abrasive or viscous materials.
• High precision labelers adapted to regulations (INCI, CLP, nutritional table).
• Machine vision systems for quality control, metal detection, etc.
• Modular conveyors for greater operational flexibility.

In regulated sectors, it is also critical that equipment is manufactured under criteria:

• GMP (cosmetics and food),
• FDA/EU (contact with food or cosmetics),
• ATEX (chemical or explosive environments).

Integrating these lines with SCADA or MES systems allows real-time traceability, OEE control and proactive alarms.

2.3. Process simulation and technical documentation

Before installing any equipment or reconfiguring processes, it is essential to simulate the scale-up to validate its efficiency and detect potential failures.

Simulation may include:

• Material and product flow.
• Production and cleaning sequences.
• Format or batch changeover time.
• Capacity of the internal logistics system.

Tools such as digital twins, 3D CAD or process simulation software (FlexSim, Siemens Tecnomatix) allow virtual testing before physical changes are executed.

Load logbook: All this analysis should be consolidated in a technical load logbook, including:

• Product specifications, speed, materials, formats.
• Regulatory and validation requirements.
• Electrical, pneumatic, hydraulic and control infrastructure.
• Cleaning, safety and maintenance criteria.
• Tolerances and expected operational KPIs.

This document will serve as the basis for installation, validation and future audits.

Result of Step 2

At the end of this step you should have:

• An optimized and validated layout.
• A selection of equipment compatible with your product, standards and production rate.
• An automation system connected to your management systems.
• Simulations and complete technical documentation to start with no surprises.

MarCoPack has proven experience in the design, manufacture and integration of customized industrial machinery for the food, cosmetic and chemical industries. From packaging, capping and labeling systems to complete line solutions, we help you transform your needs into functional, compliant and scalable solutions.

Request a technical assessment today to expand your production line and find out how to scale up without losing control.

Step 3: Implementation, validation and start-up

With the design defined and the equipment selected, it is time to turn the plans into reality. This critical phase must be executed with meticulous planning to avoid delays, quality failures or regulatory non-compliance.

3.1. Installation, assembly and integration of equipment

• Coordination with suppliers, electricians, mechanics and automation technicians.
• Verification of compliance with safety, hygiene and accessibility requirements.
• Integration of lines with control systems (SCADA, PLCs, ERP/MES).

In the cosmetics and chemical sectors, where there may be ATEX zones or clean rooms, it is essential to certify each connection and installation according to regulations.

3.2. Qualification and validation of the production system

Especially in regulated sectors, it is mandatory to validate each stage:

• IQ (Installation Qualification): ensures that the equipment has been installed correctly.
• OQ (Operational Qualification): the system is checked to ensure that it is operating according to defined parameters.
• PQ (Performance Qualification): validates that the line performs consistently under real conditions.

In food and cosmetics, this includes testing for cleanliness, sterility, dosing and labeling according to regulations (HACCP, GMP).

3.3. Team training and operational protocols

• Technical training in use, cleaning, maintenance and quality control.
• Specific protocols for format, lot or product change.
• Simulation of incidents and response plans.

A new line without trained personnel is a source of errors, downtime and regulatory risks.

3.4. Controlled start-up and continuous improvement

• Progressive start-up with intensive monitoring of KPIs (throughput, scrap, changeover time, downtime).
• Recording of incidents and corrective actions.
• Adjustment of processes, parameters and layouts based on the data obtained.

Result of Step 3

• Line installed, validated and certified.
• Trained personnel and operational documentation up to date.
• Initial production monitored, optimized and aligned with objectives.

Step 4: Scalability and future proofing

Efficient expansion does not end with start-up. A well-designed plant must be able to evolve without friction.

4.1. Modular and scalable design

• Modular equipment: allows the addition of stations without redoing the entire line.
• Flexible layouts: technical corridors, pre-installations, free areas.
• Physical and logical expandability (space, software, connectivity).

In cosmetics and chemicals, where innovation cycles are short, flexibility is a key competitive factor.

4.2. Real-time digitization and control

• Incorporate Industry 4.0 tools:
  • IoT Sensors
  • Digital traceability
  • MES-ERP integration
  • OEE monitoring
• Predictive maintenance systems to avoid unscheduled shutdowns.

Data-driven decisions make it possible to anticipate problems, optimize resources and plan future expansions with greater precision.

4.3. Internal audits and document updating

• Review technical documentation, drawings, validations and training.
• Prepare for regulatory audits (sanitary, quality or industrial safety).
• Establish annual review cycles for layout, processes and machinery.

Result of Step 4

• Plant prepared for future expansions or product changes.
• Infrastructure and equipment compatible with regulatory and technological developments.
• Company aligned with the principles of efficiency, quality and sustainable growth.

From enlargement to industrial transformation

Expanding a production line is no longer a simple question of capacity. It is a strategic decision that impacts on:

• Operational efficiency
• Product quality
• Regulatory compliance
• Brand reputation and competitiveness

By following this four-step protocol, from needs definition to future planning, your company will be prepared not only to grow, but to evolve.

In highly regulated industries such as food, cosmetics and chemicals, a well-executed scale-up makes the difference between competing or being left behind.

MarCoPack not only designs and manufactures customized industrial machinery. It also collaborates in the development of scalable and digitized production infrastructures, adapted to the pace of the market and the most stringent regulatory requirements.

Do you have a project under expansion or redesign? Our technical team can help you validate your plans, anticipate bottlenecks and build a customized end-to-end solution. Contact us!