What TEA Navigator can do for Cosmetic Manufacturing

Every technical decision has an economic consequence. TEA Navigator helps you understand both—before the investment is made.

TEA Navigator supports early-stage product and manufacturing decisions, where many alternatives are being considered and detailed business cases do not yet exist.

It links technical choices—such as formulation, process design, equipment selection, yields, energy consumption, cycle time, and aseptic processing—directly to economic outcomes including COGS and profitability. This is especially valuable during R&D and process development, when finance may not yet have built a detailed financial model.

Questions answered

• Can the process achieve the target operating margin at 1,000 t/year?
• What are the largest contributors to COGS and operating profit?
• Which unit operations contribute most to labor and operating cost?
• What production volume is required to justify the investment?
• How sensitive is profitability to botanical-extract cost?
• What HTST conditions achieve the required microbial reduction?
• How can active-ingredient retention and product quality be maximized?
• How do processing choices affect throughput, energy use, and profitability?

Economic analysis

Build the process

Create the block flow diagram for ingredient preparation, dissolving and mixing, microfiltration, HTST sterilization, aseptic filling, packaging, and finished product.

Review the P&L

TEA Navigator calculates revenue, COGS, operating expenses, depreciation, operating profit, and operating margin for the planned production volume.

Drill down into cost contributors

Review cost categories by unit operation to identify where labor, utilities, waste, facilities, and other expenses are generated.

Evaluate production scale

Determine how operating margin changes with annual production volume and identify the scale required to justify the investment.

Test ingredient-cost sensitivity

Evaluate how changes in botanical-extract cost influence operating margin across different production volumes and identify robust operating scenarios.

Computer modeling — the “T” in TEA

The same project connects economic analysis to a physics-based HTST heat-transfer, sterilization, and quality-retention model.

HTST sterilization and quality retention

Predict product temperature, microbial lethality, cold-spot performance, and heat-related quality retention during high-temperature short-time processing.

Evaluate how temperature, holding time, heat-transfer conditions, and flow assumptions affect the required 12-log microbial reduction and the retention of temperature-sensitive botanical actives.

What this example demonstrates

• One project connects formulation, process design, P&L, cost drill-down, sensitivity analysis, and process modeling.
• Packaging and ingredients can be compared with labor, utilities, facilities, waste, and depreciation.
• Production scale and premium ingredient costs strongly influence operating margin.
• HTST operating conditions create a trade-off between microbial safety and active-ingredient retention.
• Technical and economic results can be evaluated together before major equipment and process investments are made.