In 2025, Vietnam’s Beauty & Personal Care market reached approximately VND 98.3 trillion, representing an 8% increase in value (Euromonitor International, 2026). Key trends include growing demand for multi-functional products, specialised active ingredients, ingredient transparency, and continuous innovation in response to evolving skin and hair care needs. These trends are making product portfolios and formulations increasingly diverse, putting pressure on manufacturers to flexibly produce multiple SKUs and formulations on the same production lines, accurately control raw materials and dosing for each batch, while ensuring consistent quality and traceability. These requirements make the automation, connectivity, and control of production data increasingly critical.
Challenges Faced by Manufacturing Plants
- Formulation and dosing errors: Manual formulation management and ingredient addition increase the risk of incorrect dosing, cross-contamination between products, and batch rework, particularly for high-value ingredients added in small quantities.
- Packaging defects directly affecting consumers: Products with missing components, incorrect colours, misalignment, or incorrect production date codes may reach consumers if defects are not detected on the production line, leading to complaints and potential damage to brand reputation.
- Productivity pressure: The number of SKUs continues to increase while products still share the same mixing tanks and material transfer pipelines, making batch changeover time a key bottleneck in overall plant capacity.
Tan Tien’s Solutions
1. PCS 7 and Batch Control System
Design, supply, installation, and programming of a batch control system for mixing, dosing, and changeover processes.
- Applications
- Mixing and dosing tank systems
- Tank transfer and verification systems
- Material feeding systems
- CIP systems
- Adjustment of system safety and operating conditions
- Production reporting
2. Electrical and Control Systems for Packaging Lines: Implementation of electrical and control packages for high-speed filling and packaging lines.
- Scope
- Distribution panels for production areas
- Cable tray and cable ladder systems
- Automation panels for mixing tank units
- SCADA and HMI programming for packaging areas
- Power and signal cable connections to field devices
3. Machine Vision Inspection System: Automated inspection of product and packaging quality on the production line before products are released from the factory.
- Functions
- Inspection of printed codes on product components
- Detection of missing or incorrect product components
- Verification of production dates and printed codes on packaging
- Inspection of quantity and colour
- Detection of misaligned or incorrectly positioned components
- PLC program integration with equipment across the production line
4. Upgrades to Existing Control Systems: Modernisation of existing systems to improve reliability and enhance production data utilisation.
- Scope includes:
- PCS 7 program upgrades for mixing tank systems
- Development of industrial computer configurations and central PLC systems
- Integration of operator and engineering stations within a unified system
- Migration of programs and historical data
- Minimisation of production downtime during system upgrades
Implementation Benefits
- Consistent batch quality regardless of individual operators or production shifts
- Reduced dosing errors for high-value ingredients, helping lower material costs and reduce the number of batches requiring rework
- Packaging defects are detected and rejected directly on the production line before products reach consumers
- Shorter changeover times between SKUs and increased utilisation of existing production assets
- Electronic records for each production batch to support internal and corporate audits
- System upgrades carried out with minimal impact on ongoing production
In the personal care industry, Tan Tien works alongside leading global consumer goods companies such as Unilever and Procter & Gamble, delivering projects at large-scale manufacturing facilities in Cu Chi and Binh Duong. This segment involves a large number of SKUs and places high demands on formulation consistency, as multiple products share the same mixing, dosing, and material transfer systems. In particular, many ingredients are used in small quantities but are high in value and have a direct impact on final product quality.
In addition, products that come into direct contact with consumers require strict control of packaging quality and traceability throughout the production process. Tan Tien serves as an electrical and automation partner, supporting customers from the implementation of new production lines to upgrades of mixing, material transfer, and packaging inspection systems. This helps customers standardise recipe-based production processes, improve dosing and mixing accuracy, and strengthen control and data traceability across the entire production process.
