Project number
27036
Organization
Craft Beauty Lab
Offering
ENGR498-F2026-S2027
Project Overview
Craft Beauty Lab is a GMP-compliant contract manufacturer of skincare and cosmetic products. We manufacture high-viscosity products such as balms, salves, ointments, and anhydrous formulations that must be heated before they can be transferred into production filling equipment.
We are seeking a senior engineering capstone team to design, build, test, and deliver a fully functional portable heated transfer system capable of pumping hot cosmetic balms from bulk drums into a heated filling hopper.
The primary deliverable for this project is a working prototype that can be demonstrated under real manufacturing conditions.
Project Objective
Design and fabricate a portable system capable of transferring heated cosmetic balms and salves from a bulk drum into a production hopper while maintaining product temperature throughout the entire transfer process.
The system should be designed for use in a cosmetic manufacturing environment and emphasize reliability, operator safety, cleanability, and ease of operation.
Background
Many cosmetic balms and salves are solid or semi-solid at room temperature. Before filling, they are heated until they become pumpable liquids.
Current transfer methods are labor-intensive, slow, and create opportunities for product waste and operator injury.
The challenge is to develop a portable heated pumping system that maintains the product above its solidification temperature from the drum through the entire transfer path and into the filling hopper.
Functional Requirements
The completed system should:
Transfer high-viscosity cosmetic balms and salves from a drum into a heated hopper.
Maintain product temperature throughout the entire transfer path.
Prevent product from cooling or solidifying inside the system.
Include heated or insulated product-contact components as required, including:
Drum pickup assembly
Pump
Transfer hose
Valves and fittings
Discharge assembly
Operate continuously throughout a normal production day.
Be mounted on a portable cart that can be easily moved throughout the facility.
Be constructed using cosmetic-compatible materials (preferably 304 or 316 stainless steel for product-contact surfaces).
Be designed for rapid disassembly and thorough cleaning between production batches.
Minimize product loss and retained product volume.
Include appropriate temperature controls, sensors, insulation, and operator safety features.
Engineering Scope
The student team should evaluate and select appropriate engineering solutions, including:
Pump technology
Heating method
Temperature control strategy
Insulation
Structural frame/cart design
Power requirements
Sanitary fittings and connections
Cleaning methodology
Safety systems
User ergonomics
Commercially available components may be incorporated where appropriate. The engineering challenge is the successful integration of these components into a reliable manufacturing system.
Testing Requirements
The completed prototype should successfully demonstrate its ability to:
Pump heated balm from a drum.
Deliver product into a hopper at a practical production rate.
Maintain target product temperature throughout operation.
Operate continuously during an extended production run.
Restart successfully after temporary production pauses without product solidifying in the system.
Be disassembled, cleaned, reassembled, and returned to service.
Testing should be performed using an actual Craft Beauty Lab product or a representative material with comparable viscosity and melting characteristics.
Deliverables
The project should include:
Fully operational prototype
Live demonstration of the completed system
CAD models
Engineering drawings
Bill of Materials
Electrical and control schematics
Assembly documentation
Operating manual
Cleaning procedures
Preventive maintenance recommendations
Safety assessment
Test protocol and performance results
Manufacturing cost estimate for future production
Project Success Criteria
The project will be considered successful when the completed prototype can reliably transfer heated cosmetic balm or salve from a drum into a production hopper while maintaining product temperature, operating safely throughout a production day, and allowing practical cleaning between batches.
The goal is a functional, usable piece of manufacturing equipment that can be evaluated for implementation in our production facility.
Educational Value
This project provides students with practical experience in:
Mechanical system design
Heat transfer
Fluid mechanics
High-viscosity pumping
Process equipment design
Controls and instrumentation
Sanitary equipment design
Design for manufacturability
Prototype fabrication and testing
Real-world collaboration with an industrial sponsor
Craft Beauty Lab is a GMP-compliant contract manufacturer of skincare and cosmetic products. We manufacture high-viscosity products such as balms, salves, ointments, and anhydrous formulations that must be heated before they can be transferred into production filling equipment.
We are seeking a senior engineering capstone team to design, build, test, and deliver a fully functional portable heated transfer system capable of pumping hot cosmetic balms from bulk drums into a heated filling hopper.
The primary deliverable for this project is a working prototype that can be demonstrated under real manufacturing conditions.
Project Objective
Design and fabricate a portable system capable of transferring heated cosmetic balms and salves from a bulk drum into a production hopper while maintaining product temperature throughout the entire transfer process.
The system should be designed for use in a cosmetic manufacturing environment and emphasize reliability, operator safety, cleanability, and ease of operation.
Background
Many cosmetic balms and salves are solid or semi-solid at room temperature. Before filling, they are heated until they become pumpable liquids.
Current transfer methods are labor-intensive, slow, and create opportunities for product waste and operator injury.
The challenge is to develop a portable heated pumping system that maintains the product above its solidification temperature from the drum through the entire transfer path and into the filling hopper.
Functional Requirements
The completed system should:
Transfer high-viscosity cosmetic balms and salves from a drum into a heated hopper.
Maintain product temperature throughout the entire transfer path.
Prevent product from cooling or solidifying inside the system.
Include heated or insulated product-contact components as required, including:
Drum pickup assembly
Pump
Transfer hose
Valves and fittings
Discharge assembly
Operate continuously throughout a normal production day.
Be mounted on a portable cart that can be easily moved throughout the facility.
Be constructed using cosmetic-compatible materials (preferably 304 or 316 stainless steel for product-contact surfaces).
Be designed for rapid disassembly and thorough cleaning between production batches.
Minimize product loss and retained product volume.
Include appropriate temperature controls, sensors, insulation, and operator safety features.
Engineering Scope
The student team should evaluate and select appropriate engineering solutions, including:
Pump technology
Heating method
Temperature control strategy
Insulation
Structural frame/cart design
Power requirements
Sanitary fittings and connections
Cleaning methodology
Safety systems
User ergonomics
Commercially available components may be incorporated where appropriate. The engineering challenge is the successful integration of these components into a reliable manufacturing system.
Testing Requirements
The completed prototype should successfully demonstrate its ability to:
Pump heated balm from a drum.
Deliver product into a hopper at a practical production rate.
Maintain target product temperature throughout operation.
Operate continuously during an extended production run.
Restart successfully after temporary production pauses without product solidifying in the system.
Be disassembled, cleaned, reassembled, and returned to service.
Testing should be performed using an actual Craft Beauty Lab product or a representative material with comparable viscosity and melting characteristics.
Deliverables
The project should include:
Fully operational prototype
Live demonstration of the completed system
CAD models
Engineering drawings
Bill of Materials
Electrical and control schematics
Assembly documentation
Operating manual
Cleaning procedures
Preventive maintenance recommendations
Safety assessment
Test protocol and performance results
Manufacturing cost estimate for future production
Project Success Criteria
The project will be considered successful when the completed prototype can reliably transfer heated cosmetic balm or salve from a drum into a production hopper while maintaining product temperature, operating safely throughout a production day, and allowing practical cleaning between batches.
The goal is a functional, usable piece of manufacturing equipment that can be evaluated for implementation in our production facility.
Educational Value
This project provides students with practical experience in:
Mechanical system design
Heat transfer
Fluid mechanics
High-viscosity pumping
Process equipment design
Controls and instrumentation
Sanitary equipment design
Design for manufacturability
Prototype fabrication and testing
Real-world collaboration with an industrial sponsor