Equip your contract packaging facility with YohoAI's YG tube filling lines. Handle multiple clients, multiple tube formats, and multiple product types - on one machine platform.
Contract manufacturers face a unique challenge: serve clients across cosmetics, pharmaceuticals, and food industries with a single machine that must handle every tube format, every viscosity, and every quality standard. YohoAI's YG tube filling series is the OEM contract manufacturer's choice - delivering the format flexibility and changeover speed that multi-client operations demand. With recipe storage for up to 200 tube formats, tool-free changeover in under 45 minutes, and both CE and GMP certifications, the YG series eliminates the need for multiple dedicated machines. Run your cosmetics clients on Monday and your pharmaceutical clients on Tuesday - without a machine swap. The result: higher machine utilization, faster client onboarding, and better ROI per square meter of factory floor.
Verified factory data - not marketing estimates
Store up to 200 tube formats on the HMI. Each recipe stores tube diameter, length, filling volume, sealing temperature, and conveyor speed. Operators recall any client format in two screen taps - eliminating setup errors.
Tool-free changeover between standard tube diameters within the 10-60mm range takes 20-45 minutes. No change parts for most diameter changes. The fastest changeover in its class for multi-client contract manufacturers.
Process cosmetic creams, pharmaceutical ointments, and food-grade products on the same machine platform. CIP/SIP cleaning between runs meets the most stringent pharmaceutical hygiene standards. No dedicated machines required per industry.
Every production run generates a complete batch record: operator ID, start/end time, cycle count, reject count, and fill accuracy data. Records export via USB or Ethernet for client reporting. Optional 21 CFR Part 11 package for pharmaceutical clients.
Add nitrogen flushing, date coder, label applicator, or product heating system at any time without replacing the base machine. Retrofit kits ship from Shanghai within 7 days. Clients adding new product lines simply add the accessory - not a new machine.
With typical changeover times of 20-45 minutes and 200-format recipe storage, the YG series achieves machine utilization rates above 85% in multi-client operations. The flexibility to run any client format on demand maximizes billable production hours.
Our team responds within 2 hours with CIF/CFR/FOB pricing and delivery timeline.
Format changeover on the YG series takes 20-45 minutes for diameter changes within the 10-60mm range, with no tools required. Switching between products of the same tube format is even faster - simply select the stored recipe on the HMI and the machine automatically sets filling volume, sealing temperature, and conveyor speed. This enables same-day changeover between multiple client products.
Clean-in-place (CIP) and Sterilize-in-place (SIP) protocols are validated for pharmaceutical hygiene standards between production runs. The cleaning sequence (water rinse, alkaline wash, water rinse, optional sanitization) is stored as a recipe on the HMI. After pharmaceutical runs, the CIP cycle is executed before switching to cosmetics or food products. Full cleaning validation documentation is included in the IQ/OQ/PQ package.
Yes. The YG series batch record system supports multi-client operations. Each production run is logged with a unique batch number, client code, product code, operator ID, and timestamps. Reports can be filtered by client or date range and exported as CSV or PDF. For pharmaceutical clients requiring 21 CFR Part 11 compliance, electronic signatures and audit trails are available as an optional add-on.
The YG-200 handles tube diameters from 10mm to 60mm and tube lengths from 40mm to 220mm in a single machine configuration. This covers approximately 95% of standard cosmetic and pharmaceutical tube formats globally. Non-standard formats (non-round cross-sections, unique cap styles) may require custom tube holder tooling, which YohoAI can supply within 2-3 weeks.
The YG-120 pays for itself in 12-18 months for most contract manufacturers, based on: (1) avoiding the cost of 2-3 dedicated machines for different industries (the cost of two to three dedicated machines saved), (2) higher machine utilization from faster changeovers (85%+ utilization vs. 50-60% with dedicated machines), and (3) faster client onboarding (new formats operational in 20-45 minutes vs. days with change-parts machines).
The YG series is optimized for short runs. Recipe storage means no setup time for repeat orders. Tool-free changeover eliminates the change-parts bottleneck. For orders under 1,000 units, the YG-120 at 40-60 pcs/min completes the run in under 30 minutes including changeover. Batch size flexibility means you can profitably serve small clients without sacrificing margins.
Most pharmaceutical clients require IQ/OQ/PQ documentation as a supplier qualification standard. YohoAI provides a comprehensive validation documentation package covering: DQ (Design Qualification), IQ (Installation Qualification), OQ (Operational Qualification), and PQ (Performance Qualification) protocols with pre-defined acceptance criteria. The package is available in English and supports FDA, EMA, and NMPA submissions. Execution support on-site is available on request.
The 5-year total cost of ownership for a YG-120 includes: purchase price, installation and commissioning, the annual maintenance contract, spare parts, and utilities - every line is itemised in the offer. Total 5-year TCO is itemised in the offer, line by line. This compares favorably to the TCO of 2-3 dedicated single-format machines.
OEM contract manufacturing demands maximum machine flexibility and minimum changeover time. The OEM configuration supports multiple tube materials (ABL, PBL, PE, PVC) and sealing methods (hot air, cold press, ultrasonic) on a single platform. Install with adequate floor space (minimum 4m x 3m) to accommodate format change kits and material handling.
Between contract runs, perform a complete format changeover: swap tube holders, filling nozzles, and sealing jaws using the quick-release mechanism. Purge the filling system with appropriate cleaning solvent, and verify the new setup with 5-10 test tubes. Document each changeover with a setup verification checklist including fill volume, seal temperature, and photoelectric sensor calibration.
Maintain a spare parts inventory organized by tube format to minimize downtime during contract switches. Critical spares include tube holders for each diameter, sealing jaws for each material type, and filling nozzles for each volume range. Schedule deep maintenance (bearing replacement, servo calibration, electrical inspection) between major contract cycles.
Engineered for contract manufacturers that switch daily
The YohoAI OEM tube-filling platform is engineered for contract manufacturers that must switch products, tube materials, and volumes within a single shift. The dosing block uses quick-change volumetric piston cylinders in 5-250 ml (YG-120 OEM) and 10-250 ml (YG-200 OEM) sizes, with +/-1% and +/-0.5% accuracy respectively, validated by in-line checkweighing. A universal tube nest accepts 13-50 mm diameters across ABL, PBL, PE, PVC, and extruded tubes, while the sealing station offers hot-air, cold-press, and ultrasonic modes selectable per recipe. The servo-driven indexer and colour-touch HMI hold up to 200 format recipes, automatically adjusting fill volume, dwell time, and seal pressure. Product-contact surfaces are 304 stainless steel with tool-free disassembly for CIP, and the open-frame design gives operators full access during multi-product campaigns without cross-contamination risk.
Match budget to compliance needs
Three build levels let contract manufacturers match budget to compliance needs. The Standard configuration handles a single tube type at 45-90k USD with no validation package - suitable for private-label cosmetics. The OEM configuration (55-120k USD) adds multi-product flexibility, 10-15 minute changeover, and two or more sealing options for diverse client briefs. The GMP configuration (60-130k USD) adds 316L contact parts, IQ/OQ/PQ documentation, and audit-ready batch records for pharmaceutical clients. Changeover stretches from 10-15 minutes on the OEM to 20-30 on the GMP build because of added clean-in-place verification steps. Most contract packers choose the OEM tier as the default and specify GMP only for pharma-dedicated lines, avoiding the cost of validating flexibility they do not need.
Maintenance centres on hygiene and contamination control
Because OEM lines run many different products, maintenance centres on changeover hygiene and contamination control. After every product switch, fully strip the dosing piston, filling nozzle, and tube nest, then CIP-rinse and dry before the next SKU. Daily checks cover the pneumatic lubricator, sealing-head cleanliness, and a five-tube trial fill. Weekly: inspect O-rings and gaskets for flavour or colour carry-over, and verify photoelectric registration on the new artwork. Monthly: replace sealing plates by volume, lubricate the servo guide rails, and recalibrate dosing. YohoAI keeps a contract-manufacturing spare kit - pistons, nests, seals, belts - in Shanghai for 48-hour dispatch, and the optional annual service plan adds two engineer visits plus priority remote diagnostics to keep multi-client schedules on track.
Two YG-200 OEM lines for a CDMO
A Southeast Asian contract development and manufacturing organisation (CDMO) installed two YG-200 OEM lines to serve pharmaceutical and cosmeceutical clients requiring 316L contact parts and full IQ/OQ/PQ. Running topical gels and creams in ABL and PBL tubes at 110-130 pcs/min, the plant achieved +/-0.5% fill accuracy across 10-250 ml volumes. The configurable sealing station handled both hot-air and ultrasonic formats for different clients without hardware change. Integrated coding and 21 CFR Part 11 batch logging satisfied three separate regulatory audits in the first year. By consolidating previously outsourced filling, the CDMO cut lead times from 21 to 9 days and lifted gross margin on contract work by 14 percentage points, prompting a third-line order within 18 months.
