“It’s Been Tremendous!”
Production Consultation Enables 25% Productivity Improvement at Mayfield Laboratories
Mayfield Laboratories, part of Natural Looks Trading Ltd., specialises in luxurious, naturally inspired toiletries, fragrances, and hair and skincare products. Their entire range is manufactured at their UK facility, with products distributed worldwide.
After more than 35 successful years in business, Mayfield Laboratories’ next phase of growth is being driven by Peter Darke, an experienced industry professional specialising in the development and optimisation of manufacturing operations.
To refine existing processes, increase efficiency, and improve production flow, Peter consulted with Dean Willis, Sales Director of Adelphi Manufacturing.
Experience-Led Advice, Not Hard Selling
“I’ve been doing this for quite a few years now!” Peter laughs. “And to be subjected to hard-selling of machinery and equipment is really unpalatable. I prefer to use my network of experienced contacts to support my own knowledge and help me achieve the desired improvements.”
Peter values Dean’s years of hands-on experience assessing manufacturing equipment and identifying opportunities for optimisation.
Dean and Peter each bring over 30 years’ experience in the cosmetics and personal care process and packaging industry. Their strong rapport - built on shared industry history - allows for open, practical discussions grounded in real-world manufacturing insight.
“If you just sell, without support, you won’t last long,” Peter declares. With Adelphi Manufacturing celebrating their 75th anniversary in 2022, this philosophy clearly underpins their approach.
Improvement 1 – Fill Speed Adjustment
During his initial consultation visit in 2021, Dean advised Production Manager Kate Reeley to increase the filling speed of the Adelphi Response Benchtop Fillers. This adjustment addressed air pockets appearing in a body lotion product.
The benefits were immediate:
- Improved product appearance
- More consistent fill weights
- Increased throughput from 16 to 25 bottles per minute
- Over 500 additional bottles per hour
Kate’s verdict:
“We noticed the improvements straight away. We get much more out of the machines than we did before. We use them every day - there’s always one or two Responses running!”
At Dean’s follow-up visit in 2022, Kate demonstrated a men’s shower gel product. During their conversation, 1,000 units were fully processed and ready to ship.
Improvement 2 – Hopper Adaptation with Electrical Sensor
General Manager Lucy Poole highlights the success of a hopper adaptation suggested during Dean’s first visit - an electrical level sensor that detects when product is running low and automatically tops up the hopper from the feed drum.
Mayfield Laboratories initially implemented the adaptation on one hopper to prove the concept. The result?
“Fantastic!”
Lucy notes that the Response filler has since become the team’s favourite machine, surpassing others previously preferred.
Key Benefits:
- Safety: Reduced need for operators to climb ladders
- Hygiene: Eliminates double-handling of product
- Efficiency: Frees operators to assist elsewhere in production
Lucy also observes that the single-shot fill capacity of the Response is higher than previously realised, allowing it to handle more of Mayfield’s product range - including traditionally challenging high-viscosity body scrubs.
Dean confidently adds, “The machine runs well on scrubs.”
Lucy responds, “It runs well on everything!”
Assistant Supervisor Julia reinforces this:
“You can rely on them more than any other machine. You set the fill volume, and once it’s there, it stays there. They’re also easier to strip than any other machine we have.”
Minimal downtime is critical, as Mayfield Laboratories fills batches ranging from 500 to 10,000 units, across an exceptionally diverse product and container portfolio.
Improvement 3 – Eliminating Product Waste from Nozzle Dripping
During his 2022 return visit, Dean addressed an issue with a silica-based anti-frizz hair serum, which had been dripping between fills and causing unnecessary product waste.
Although the sticky nature of the product presented challenges, the correct solution was identified and implemented successfully, leaving all parties satisfied with the outcome.
The Overall Verdict
“It’s made a huge difference,” says Peter. “There’s been a real step forward since Dean came in and helped - it’s been tremendous.”
He adds: “Throughput is so much better since Dean’s training and adjustments - around 25% more productive overall.”
Dean’s approach of delivering “bite-size chunks of improvement” has provided Mayfield Laboratories with a practical wish list of actionable enhancements, allowing the team to assess cost, benefit, and feasibility over time.
Lucy highlights Adelphi’s ongoing support:
“If we’re bringing out a new product, we know we can ask your advice about how best to fill it - we can always pick your brain!”
Built on Quality, Driving Continuous Improvement
Founded over 35 years ago, Mayfield Laboratories remains a family-owned and run business, with an enviable industry reputation for quality, reliability, and customer care.
Now progressing toward further ISO and GMP certification, the team demonstrates a strong culture of continuous improvement. Recent investments include:
- Two additional production units
- An in-house formulation chemist
- A portfolio exceeding 1,000 formulations
Dean - and Adelphi Manufacturing as a whole - are proud to support Mayfield Laboratories with responsible, experience-led advice, helping businesses balance cost, output, and operational gains to achieve sustainable future growth.
We look forward to continuing this successful partnership long into the future.
