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The cosmetics factory
brain

One AI layer across every machine on the line — from unscrambler to palletiser. Captures every operator action, machine event, and SKU recipe. Serves the right answer to the right operator, on the surface they already use.

PackGuru on the production line
LIVE · UNILOGO L1
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SOC 2 CertifiedISA/IEC 62443GDPREU AI Act ready · Aug 2026
PackGuru on the production line
LIVE · UNILOGO L1
30+
Languages supported
24/7
AI-powered assistance
99.5%
Platform uptime SLA
40d
Pilot to deployment
Knowledge graph

Every action, event, and recipe on your line — in one searchable graph

Drag to explore. Click any node to see what PackGuru captures from it

The whole line

One factory, twelve dashboards, zero answers at 4am

Every machine on your line generates data. Most of it never leaves the cabinet. The signals that matter are scattered across twelve OEM HMIs, three SCADA screens, and the heads of two senior operators who retire next year. PackGuru pulls it into one layer — and serves the answer to the operator who needs it, on the surface they already use

One AI brain · Every brand on the line · OPC-UA · Modbus · MQTT · B&R · Rockwell · Siemens · Schneider Electric

01 / The problem

Every hour, your line quietly eats 0 minutes

No alarm fires. No one logs it. Micro-stops, slow ramp-ups, unguided changeovers — at 100 bottles a minute, that's 1,700 bottles a shift you made and never shipped. Three leaks, same pipe:

01 · Recurring

Knowledge walks out the door

Your most experienced operators carry years of expertise in their heads. When they retire, every shift after that runs on guesswork — and the next changeover takes twice as long. PackGuru captures what they know before it leaves

02 · Recurring

Downtime costs thousands per hour

A line stopped at 100 bottles a minute is 6,000 bottles an hour you made room for, staffed for, and never shipped. PackGuru's live monitoring and instant troubleshooting cut response time from hours to seconds

03 · Recurring

Data you have isn't being used

Your machines generate thousands of data points every minute. Almost all of them die in the cabinet — while the losses they could have flagged keep repeating, shift after shift. PackGuru turns that stream into the top three actions that stop the bleeding

02 / What PackGuru does

One platform, every layer of your operation

Knowledge Platform

Turn operator expertise into structured training. Video tutorials, multilingual courses, progress tracking — ready in minutes

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Live Monitoring

Connect PackGuru to WhatsApp. Get instant alerts. Resolve faults before they become stoppages

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Condition-Based Maintenance

Monitor pump temperature, vacuum levels, and O-ring wear in real time. Act before failure happens

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Data & Process Analysis

Daily AI reports following the 4M methodology. Golden recipe management. Speed loss diagnostics

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Robotic Floor Assistant

Roberta is the senior operator who never goes home. Patrols autonomously. Voice-activated by "Hey PackGuru". Knows every SOP, every alarm code, every recipe drift. Tells your operators exactly what to do — in their language, at the machine — so the line keeps running

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Enterprise Security

Zero-trust architecture. OT/IT segregation. TLS 1.2+. SOC 2 certified. Ready for your IT audit

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03 / Knowledge platform

The knowledge is already in your factory — PackGuru makes it teachable

Film your best operator doing the job. PackGuru turns that recording into a professional micro-learning module — dubbed in 30+ languages, with auto-generated quizzes, available to every operator on every shift

Capper Changeover · Module 03 of 07
ENPLPT-BRESDE+26
LIVE RECORDING · MICRO-LESSON
Quiz · Question 2/5
When adjusting Overpick Height on the Delta robot, which value is recommended for curved caps on KPR1?
A 28.0 mm
32.0 mm
C 36.0 mm
D Auto-detect

Video Tutorial Generation

Upload a phone recording. PackGuru segments it into 60–90s micro-lessons, generates quizzes, and publishes in your languages — within two minutes

Course Builder

Drop in manuals, SOPs, schematics. PackGuru structures them into interactive modules with auto-translation and visual aids

Progress Tracking

A single dashboard of every operator's training status — videos watched, quizzes scored, XP earned. Filter by role, line, shift

Multilingual Dubbing

Full voice dubbing — not subtitles — in 30+ languages. Documents translated preserving structure and images

Immersive 360° Learning

Operators rotate the view, orient themselves inside the real environment. Works on tablets, phones, Apple Vision Pro

Safe Knowledge Sharing

Share courses across factories without losing control of who sees what. Anti-theft mechanisms protect proprietary procedures

04 / Live monitoring

At 4am, operators don't log into systems — they send a WhatsApp

If the answer isn't there, they wait — and the line stays down. PackGuru is already in the group, responding in seconds with video analysis, proactive alerts, and step-by-step guidance

9:41
‹
L1
Cleanline L1 · Night shift
PackGuru · 4 operators · 1 supervisor
TODAY · 02:14
Message

Communicator integration

No separate app, no login. Works on the phone operators already carry. Analyses video messages to diagnose faults instantly

Live troubleshooting

Voice, text, or photo via "Hey PackGuru". Specific contextual answers — not search results, actual steps. In 30+ languages, on HMI, tablet, phone, or via Roberta

Changeover tracking

Step-by-step digital guide for every A→B switch. Photo checks against reference. Machine signals log timing. Operator efficiency linked to training level

Living knowledge base

Every resolved OEM conversation automatically logged and made searchable. The system gets smarter every shift

Delta robot vacuum gripper picking a cosmetic cap, frozen mid-pick
[ 100 picks a minute · every one watched ]
05 / Condition-based maintenance

Reactive maintenance is the most expensive kind

A worn spring. A clogged vacuum hose. A failing O-ring. None of these fail suddenly — they degrade gradually until the line stops. PackGuru watches the signals

Pump temp

AC Motor Overheat Protection

Foam from closure transport reaches the capper vacuum, gradually clogging it. PackGuru monitors pump temperature continuously and flags before failure

Not just detection — root cause. PackGuru suggests the specific correction action based on running format
Vacuum

Vacuum Pipe Control

Tracks pick time across 8 robots, identifies degrading conditions suggesting a hose issue. Notifies maintenance and OEM via WhatsApp. DMS integration auto-creates work orders

Replace the hose before it affects productivity — not after
O-rings

Filler O-Ring Wear Detection

Detects early indicators by monitoring pressure profiles — unexpected fluctuations, drops, increased fill times — and alerts before significant product loss

A failing seal caught early vs. mid-shift = thousands of units of product saved
Vision

Vision System Training Data

When a 6-axis robot collides with a misplaced cap, the 10 preceding photos are auto-recorded and fed back into vision retraining

Fewer collisions = fewer stoppages = more bottles per shift
Case study · Cap Sorter

Up to 960 bottles/hr recovered through maintenance alone.

Worst case: 70+ missed picks per robot, per hour. Root cause: burned LED stripes and belt dirt creating shadows that confused the vision system.

01
Weekly cleaning procedure
Sorter belt protocol scheduled and tracked
02
Backlight inspection
LED stripe health monitored across shifts
03
Automated filter check
Triggered when missed picks exceed threshold
06 / Data & process improvements

Your line generates thousands of data points every minute — most are ignored

PackGuru turns them into a daily briefing — exactly where to focus, what to fix first, and what the expected gain will be

Daily AI Report · Line 4 · Personal Care
Shift end · 17 May 2026 · Auto-generated
4M Methodology
Critical loss · top contributors
Rotary filler
−880 b
Inline capper
−510 b
P-S labeler
−340 b
Checkweigher
−190 b
Root cause · 4M classification
Man
36%
Machine
21%
Method
31%
Material
12%
Top 3 actions · 80/20 focus
01Flush rotary filler dosing valves — viscosity drift on last 3 batches causing underfill
02Re-torque inline capper chuck heads — torque variance ±0.4 Nm above spec
03Verify P-S labeler web tension after reel change — label skip rate up 2.1%

Root Cause Analysis (4M)

Every issue categorised by Man, Machine, Method or Material. Critical losses quantified in units. Top three actions address 99% of losses

Golden Recipe Management

If the line ran perfectly last Friday but is underperforming today, PackGuru highlights every parameter difference between now and the last known high-performance configuration

Speed Loss Analysis

Deep-dive into every module. Ramp-up assessment from changeover to stable production. Performance oscillation analysis to find downstream blockages

Ask Your Shift

"Show me time spent in Execute and Aborted states for L1 on the 17th of May." PackGuru pulls data, charts it, breaks it down by hour. No SQL

07 / Roberta

The right knowledge, at the right place, at the right time

Roberta is a mobile robot powered by the PackGuru AI Field Production Advisor. She patrols production lines autonomously, responds to "Hey PackGuru", and brings expert knowledge directly to the point of need

Roberta — PackGuru AI Field Production Advisor on the factory floor
[ photo · OrionStar GreetingBot Nova · Unilogo factory ]
Autonomous patrol with scheduled observation stops
Voice activation via "Hey PackGuru" wake command
On-screen SOPs, manuals, training videos
Live video stream to remote technical experts
NVIDIA edge compute for offline resilience
01

Patrol Mode

Patrols autonomously. When a machine stops and no operator action is detected, navigates to the area, records the situation, documents fault and response

Output → root cause dataset
02

Changeover Assistance

Records the full action sequence during changeovers. Compared against the standard procedure to create real-floor training material

Output → standardisation, shorter changeovers
03

Troubleshooting

If no operator action 5 minutes after a stoppage, Roberta navigates to the problem area and displays the correct procedure at the machine

Output → right knowledge, right place, right time
04

Weak-Point Monitoring

Stations herself at the highest-risk point of the process — defined by known jam areas and the SKU currently running

Output → earlier detection, contextual guidance
Architecture · Three layers
L1 Mobile platform — Autonomous nav, 3D LiDAR, cameras, mics, touchscreen, safety sensors.
L2 PackGuru AI engine — NLP, SOP retrieval, video streaming, incident tagging, voice interaction.
L3 NVIDIA edge module — On-device inference, low-latency processing, offline fallback when WiFi fails.
Humanoid robot performing a changeover on a cosmetics packaging line
WHERE THIS IS HEADED
Roberta is step one. The PackGuru AI engine is platform-agnostic — as humanoid robotics matures, the same knowledge runs the same line. New hands.
08 / Implementation

From contract to go-live in 24 weeks

We don't hand you software and walk away. PackGuru is installed, configured and validated inside your factory by engineers who understand both IT/OT security and the realities of a production floor

STEP 01Phase 1 · W1–4Commercials & ScopeKick-off, OEM dependencies confirmed, scope locked. Everyone aligned on what is in and what is not
STEP 02Phase 2–3 · W5–8Knowledge BaseFactory structure, roles and access configured. Documentation, schematics and training videos uploaded
STEP 03Phase 4–5 · W9–12Factory ConnectivityGateway installed, secure ping confirmed, security signed off. OT network isolated. DMZ bridge established. TLS 1.2+ on 443
STEP 04Phase 6 · W13–20Line TelemetryNVIDIA Jetson installed inside control cabinets. Machine signals mapped via Modbus, OPC-UA, MQTT
STEP 05Phase 7 · W17–24Go-Live with HypercareAlert thresholds tuned. Every alert validated in real production. UAT sign-off. The line is yours
Security architecture

Your PLCs never talk to the internet

Zero inbound ports
PackGuru connects to your machines without opening a single inbound port
One-way data flow
Information leaves the factory through a secure DMZ bridge. Nothing comes back
Encrypted everywhere
All data over TLS 1.2+ on standard port 443. No custom firewall rules
Audit-ready
ISA/IEC 62443, SOC 2, GDPR. ISO 27001 on the roadmap
09 / Compliance & Trust

Built in the EU — audited for August 2026

PackGuru is engineered against EU AI Act high-risk system requirements. Data lineage, human oversight, and traceability are not bolt-ons — they are part of the architecture

EU AI Act · August 2026

High-risk system compliant

PackGuru operates in a regulated production environment. Audit trail on every AI output. Human operator remains the decision point. Full documentation package available on request

Data residency

Your data stays yours

EU-hosted infrastructure. Customer-owned factory data. No cross-tenant model training. Golden recipes and operator knowledge belong to your factory — PackGuru is the safe, not the source

Existing certifications

ISA/IEC 62443 · SOC 2 · GDPR

OT/IT security architecture certified. Zero inbound ports to the production network. ISO 27001 in progress. Full security documentation provided at contract stage

EU AI Act · Aug 2026ISA/IEC 62443SOC 2GDPREU-hostedISO 27001 in progress

Questions from your IT security or legal team? We have the documentation

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Ready to transform your operations?

We'll show you exactly how PackGuru would work with your machines, your operators, and your production challenges.

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