We’re often approached by companies that are very interested in manufacturing fragrances as a new business venture, or for use in their products, but they want to start out with small volumes, to see if it’s a good fit, before heavily investing in a full scale manufacturing facility. They also tell us they would like to use only the essential ingredients necessary and cut out all of the extra chemicals for eco, sustainability, and cost considerations.
We’re approached by other manufacturers that have a desire to ramp up or down quickly to satisfy large project requirements from a recent award, but shipping finished product is now eroding any chance of high margins. They want to discuss manufacturing on or near their customer’s location, use in country resources, have the flexibility to source ingredients globally, gain local content %, and reduce overall shipping charges, while gaining independence from large fragrance houses.
In order to help our customers grow their businesses and control all aspects of manufacturing, we’ve created a mobile, on demand compounding system that we call, Fragrance Factory in a Box.
Our on-demand fragrance production line that is crafted into a 40 foot shipping container. This is a fully functional manufacturing facility, that starts with raw materials, then weighs, measures, compounds, and packages product for use internally or for sale externally.
On Site, On Demand Fragrance Manufacturing
FFIB was designed for domestic and international transportation. The fact that it can be loaded on a flatbed, or railcar, or ship, makes this a truly invaluable option to quickly ramp up and manufacture when it’s needed most. Once the container is delivered, and you add power and local raw materials, you are ready to manufacture.
The ability to source raw material anywhere in the world is the flexibility many companies and their supply chains have been searching for.
While FFIB was designed for smaller batches, its modular design allows users to string several containers together to rival the manufacturing horsepower of large factories.
Manufacturing fragrances on-site & on-demand: In the name of sustainability, transparency, and reducing the overall carbon footprint, we see a bright future with our dynamic model, allowing companies of all sizes to manufacture small batches on site, while making minor changes on demand, and creating new and unique fragrances.
1 – Definition: Fragrance Factory in a Box is an on demand fragrance compounding system built for manufacturing fragrances and the rapid deployment of equipment. (FFIB) is directed to manufacture fragrance compounds, set forth above, for various fragrance & flavor applications.
2.2 – Our system contains 4 training & technology parts, each of which can be licensed individually. It will in many cases be necessary to provide on site training to new employees, especially employees new to chemical compounding in country in regards to: understanding the formulas components, weighing, mixing, blending, and packaging. Our system contains the following training and intellectual property options that can be licensed individually:
We have broken these training and technology support into 4 key parts, each of which can be licensed individually if needed.
(1) An intellectual property/technical solution / 30,000 formulas
(2) A logistics solution / shipping containers via a freight forwarder
(3) A training solution – we provide onsite training, how to properly weigh raw materials, how to mix raw material, package, etc.
(4) A methodology for quality control testing as well as additional on-site compounding assistance. The beauty of this system is the manufacturing and production plant that embodies 4 containers. These 4 containers can be shipped separately, and when in country or located at a customer’s manufacturing facility, are seamlessly assembled together to form a fully equipped manufacturing plant, capable of overflow manufacturing, single and multiple fragrance, flavor, or product manufacturing, on demand, and anywhere in the world.
- A. Container #1: Office / Intellectual Property / Qa /Qc lab / Label Printers
- B. Container #2: Manufacturing Equipment (Mixing tank, Scales, Handling Equip
- C. Container #3: Raw Materials / Rack Storage System) allows shipping trade secret mixtures or confidential components in part A and having in country personnel complete the fragrance with part B. increases local content percentage & includes smart tracers.
- D. Container #4: Finished goods /Packaging containers
The system is a practical solution for manufacturing fragrances on demand at any location in the world and provides a manufacturing solution to greatly increase in country manufacturing content or local content requirements. the three factories with different levels of automation setups are described below.
(Automatic production, Semi automatic production, & Manual production)
It is concluded within manufacturing strategy that competing on the basis of one or two capabilities as suggested by a trade-off model is no longer acceptable. Stronger and better performing companies are competing on the basis of multiple capabilities.
2.3- Innosol’s Fragrance-Factory-in-a-Box 1 – Automatic assembly with focus on flexibility
Our Fragrance-factory-in-a-Box System has been developed and demonstrated within a robotics production system using an automated production module to compound fragrances. The overall goal of this system was to develop an automatic production module, which compounds fragrance oils, while meeting the overall Fragrance-factory-in-a-Box requirements of flexibility, speed, and mobility:
• Flexibility: in order to compound different variants of fragrances with short set-up time, it is necessary to have flexible equipment and fixtures. There is a need for the ability to reconfigure the module and its components while still having a robust and efficient manufacturing.
• Speed: Short set-up time is vital for the success of this system. The fragrance- factory-in-a-Box system will enable a structured production requirement process and a support for design of future fragrance oils.
• Mobility: Our Fragrance-factory-in-a-Box module is designed as a “Mobile Platform” to be moved anywhere within the owners system. Possibly also moved to a supplier or customer site. The vision of this system has been a production system that can be assembled and configured according to various needs and that can be delivered to any location.
Fragrance-factory-in-a-Box #1
The focus of our system has been to create Modules that are easy to transport to the production site as well as to move them at the site, e.g. external and internal mobility.
• Re-configurability: in order to meet changing demands and automatic/ semi- automatic configuration of modules and system are prerequisites for scalability for changing production volumes and for fast ramp up of production.
• Reusability: of system components and modules together with simple and fast programming makes conditions for faster and cheaper system solutions and system robustness towards disturbances, especially during ramp-up of production. The reusability also makes it possible to achieve a profitable reduction of production capacity. This is as important as the ability to increase the capacity. The reusability makes it possible to reuse the equipment in other applications in the same or in other companies. Many companies hesitate to invest in new production capacity/equipment because of the financial risk involved in the case of future declining production volumes.
Manufacturing
• Standardized: hard and software interfaces and integrated highly flexible production equipment, integrated metrology, and sensor based calibration, combined with sensor-integrated robotic filling equipment control are prerequisites for flexibility/agility. Our fragrance-factory-in-a-Box system for automatic fragrance compounding consists of a metered dispensing station, and integrated handled tools. Material and components, supplied to the module from stock, are oriented and automatically filled by flexible automatic equipment.
The container is flexible, using flexible equipment, and designed for re-configurability. Through technical solutions, supporting mobility and flexibility, the requirements of speed are achieved by e.g. quickly reconfiguring the container at another location and /or introducing a new product.
2.4- Fragrance-Factory-in-a-Box 2 – Semi-Automated Compounding with a focus on mobility
Fragrance-factory-in-a-Box 2 is a semi-automated manufacturing container, which is used for compounding numerous fragrances in one location. all machinery will be fitted into a standard container, which also will contain, fume hood exhaust, lighting, computer terminal etc.
Fragrance-factory-in-a-Box 2 has approached the key projects flexibility, mobility, and speed as follows:
• Flexibility: in order to compound different variants of fragrances with short set-up time, it is necessary to have flexible equipment and fixtures. there will be a need for reconfiguring the module and its components while still having a robust and efficient manufacturing.
• Speed: there is a need to quickly reconfigure the module without long set-up time. Operations should be started as soon as possible after movement within the manufacturing system or transport to site. the fragrance-factory-in-a-Box system will reduce the compounding time compared with setting up a new facility. Quality will be improved and the speed of manufacturing will increase.
The greatest news value of fragrance-factory-in-a-Box 2 is the usage of known technologies in all new applications and context. this kind of mobile fragrance manufacturing could make a great asset for a lot of different customer or overflow manufacturing where space is major constraint.
Manufacturing
Fragrance-factory-in-a-Box 2 can perform the following operations;
• Compounding many different fragrances at one location
• Manual compounding (weighing, blending, packaging, shipping)
• Our Fragrance-Factory-in-a-Box 2 will also contain a device to suction fumes.
• Standardized: hard- and software interfaces and integrated highly flexible production equipment, integrated metrology, and sensor-based calibration, combined with sensor-integrated robotic filling equipment control are prerequisites
The fragrance-factory-in-a-Box system for automatic fragrance compounding consists of a metered dispensing station, and integrated handled tools. Material and components, supplied to the module from stock, are oriented and automatically filled by flexible automatic equipment.
The container is flexible, using flexible equipment, and designed for re-configurability. Through technical solutions, supporting mobility and flexibility, the requirements of speed are achieved by e.g. quickly reconfiguring the container at another location and /or introducing a new product.
2.5- Fragrance-Factory-in-a-Box 3 – Manual compounding with a focus on rapid response, local content & mobility
(Covid 19 –rapid response, overflow, and customer training on site are all reasons to choose this option. Any fragrance can be created using this manual system as long as you have the raw materials and can source them locally. This option gives you complete flexibility to manufacture any fragrance on site, show your customer how scents are created on their site without having them travel to your location, or train new employees on site before shipping the modules out of the country.
If you would like to test the waters and see if manufacturing fragrances on site would be a viable option, without spending millions on buildings and infrastructure, this is the winning solution you have been searching for. The ability to ramp up fragrance production in remote areas in days, not months, is priceless and also allows shipping confidential components in part a and having in country personnel complete the fragrance with part B. (30-40% of fragrance oils use 1 carrier oil, which is usually very easily sourced in any country – which can be mixed as part B in other countries without giving away the formula.)
Many of our customers have strong desires about placing some part of an import order within the borders of the customer’s home country. By sending our Factory-in-a-Box, Innosol fulfills this production relocation desire and yet maintains control over the production. This can lead to winning orders in markets otherwise closed, which will create job opportunities not only for foreign countries, but also for users in the US since the main part of the order is produced here.
Innosol is facing a market where the customers are becoming more and more powerful due to the tough global competition. Many customers have strong wishes that part of the production should be carried out locally (local content requirements (lcrs)), in order to create new jobs. instead of building factories, which may be abandoned as soon as the order is processed, Innosol and our Fragrance-Factory-in-a-Box System aims to expand our mobile production facilities, which can be re-located as soon as the production of an order is finished.
Fragrance-Factory-in-a-Box 3 is based on manual compounding, flexibility, mobility, and speed as follows:
• Flexibility – Different variants of products with short set-up time require flexible equipment. There is a need for reconfiguring the module and resources to a customer specific product while still having a robust and efficient manufacturing.
• Mobility – Our Fragrance-Factory-in-a-Box system is designed as a “Mobile Platform” to be moved anywhere and reused for a new customer and a new project.
• Speed – Short set-up time is vital for the success as well as readiness for transportation.
Our Fragrance-Factory-in-a-Box, on demand and mobile production system, can be used to reallocate working opportunities in a cost-effective way when the customers demand this as a part of the business deal.
A fully developed Fragrance-Factory-in-a-Box enables a substantial reduction of resources needed for sharing experience and knowledge compared with a conventional outsourcing strategy.
There are two technical solutions for moving and housing production capacity abroad: special containers and a modular building solution. the choice of final solution will be decided upon including a prognosis on usage frequency, production capacity needed, and the strategically value this solution gives each user.
Besides being used as a value add or enabler to win orders, our Fragrance-Factory-in-a-Box system provides a substantial potential for cost-cutting in ongoing production.
In Summary
All you need is one or more employees to weigh ingredients, blend, and package. Or if you prefer, we can provide you with full automation, where one touch of a button produces a batch from start to finish.
In the name of #sustainabilty, #transparency, and reducing the overall carbon footprint, we see a bright future with our dynamic model, allowing thousands of companies to manufacture small batches on site, making minor changes on demand, and creating new and unique fragrances.
About Us:
Innosol, Inc., America’s leading flavor and fragrance company, today announced it is licensing on demand factories in 2022. This is further proof of Innosol’s commitment to leverage growth potential for small to mid sized manufacturers in the US, Europe, and Asia.
Designed to deliver a superior level of flavor and fragrance solutions, these new on demand facilities will enable Innosol and it’s partners to meet growing demand from customers in the personal care, candle, industrial, and food and beverage segments.
“Over the last few years, there has been tremendous growth in mergers and acquisitions, and independent perfume manufacturers are disappearing. This leaves small to mid sized manufacturers at a disadvantage. Given this rapid transformation, we are offering our on demand factories, a proven solution, to address the needs of these markets and clientele.”
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