Unilever’s factory in Bydgoszcz has launched one of the most automated production lines in Europe, capable of producing up to one million packages per week and handling over 20 different packaging formats. More than 90 percent of the plant’s output is destined for foreign markets, mainly in Western Europe.
The new installation sets a new benchmark for flexibility in cosmetics manufacturing. While industry standards typically allow two or three formats per line, and four is considered flexible, the Bydgoszcz line operates with over 20 formats, from 50 ml to 750 ml bottles. Products include shampoos, conditioners, shower gels, creams, and facial tonics. The line runs 24/7 in continuous mode.
A leap in flexibility and automation
– The scale of flexibility of this installation significantly exceeds market standards. In the cosmetics production industry, one line usually handles two or three packaging formats, and four are already considered flexible. Until recently, the maximum in the Bydgoszcz factory was seven formats. The new installation multiplies that level several times, setting a new standard – said Jakub Majchrzak, Technical and Transformation Manager at the Unilever Bydgoszcz factory.
Advanced automation and robotics are key to achieving such versatility. The line can quickly switch between different product types, reducing changeover times and enabling rapid portfolio adjustments. This allows the factory to respond faster to market trends and introduce limited editions or seasonal variants without major production interruptions.
Boosting export potential
Bydgoszcz has long served as a strategic production hub within Unilever’s European network. With over 90 percent of output exported, the new line strengthens the plant’s role in supplying key markets such as the United Kingdom, Italy, and the Netherlands. The ability to handle more than 20 formats makes it easier to tailor products to local preferences and regulatory requirements across different countries.
– The new installation increases the plant’s export potential. With over 20 packaging formats, the factory can efficiently prepare products tailored to different markets and faster introduce limited editions or seasonal variants. The flexible line allows better use of production capacity, faster response to market needs, and at the same time increases the competitiveness of the entire plant – said Jakub Majchrzak.
The investment reinforces the position of the Bydgoszcz factory as a cornerstone of Unilever’s European manufacturing strategy, capable of meeting growing demand for customized and fast-changing product portfolios.
Źródło: WNP.PL, Fot. Unilever (materiały prasowe)
