Challenges with the Changeover of Packaging Machines
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Within every minute that passes, there is a flood of Consumer Packaged Goods (CPG) released in the world, along with different packaging designs and sizes to meet consumer demand.
It is not practical that a food and beverage manufacturing company can purchase and install for each of the products launched a specific packaging machine, which requires such a strong cash flow that even the world’s largest companies in the sector may not even be able to afford it. In this sense, final users of packaging machines frequently expect that the machine purchased can be used for a wide range of sizes and formats of products.
New food and beverage products, sizes, and packaging designs pose a challenge for production due to shorter runs and increased changeovers, impacting line efficiency and profitability. Rapid and accurate changeovers are crucial, especially for small- to medium-sized companies accommodating multiple changeovers in a single shift. Adapting quickly to changeovers in secondary packaging lines is a must-have capability, with pressure to maintain speed, and agility while keeping per-unit costs down.
In this article, we talk about the primary challenges that food processing and manufacturing companies faced during the changeover with their packaging equipment.
Topics:
- What is the size changeover with the packaging machines?
- What are the potential problems with the size changeover of packaging machines?
- What are the recent technologies that can facilitate the changeover with packaging machines?
What is the size changeover with packaging machines?
Changeover of packaging machines is a process that every food and beverage manufacturer must face.
It involves stopping production and carrying out commissioning again the packaging machine to switch between different packaging formats or products.
Examples are as follows:
- Adapting a wrap-around sleever for yogurt cups from 1*2*1 multipacks to 1*3*1 multipacks
- Adjust a cartoner machine so it can work for a different carton box size large than the previous one
- Change the format of a case packer so that it can pack more carton boxes in a larger corrugated case or RSC
Changeover with a packaging machine can be time-consuming, costly, and risky now that it requires skilled personnel to do it and frequently entails downtime and failure of repeatability.
Why Fast Changeover is Important with Packaging Equipment?
Fast changeover is an essential aspect of packaging machines as it helps companies to reduce downtime, increase productivity, and meet customer demands for a variety of products. According to Packaging World, “a fast changeover time can mean the difference between meeting orders and losing business” (Packaging World, 2019).
Companies expect fast changeovers to minimize the time required to switch from one product to another, which allows them to produce smaller batches more frequently and respond quickly to changes in customer demand. This can lead to increased efficiency and profitability, as well as improved customer satisfaction.
Moreover, fast changeovers are crucial for lean manufacturing processes, as they help to eliminate waste and reduce costs. By reducing setup times, companies can reduce the amount of inventory needed to meet customer demands, and avoid overproduction, waiting, and excessive transportation.
According to a study conducted by the National Institute of Standards and Technology (NIST), reducing changeover time can result in significant cost savings for manufacturers. The study found that “reducing the average setup time by 50% could result in a 33% reduction in work-in-process inventory, a 38% reduction in machine downtime, and a 63% reduction in production lot size” (NIST, 2005).
The fast changeover is critical for packaging machines as it enables companies to increase productivity, improve efficiency, and reduce costs. It also plays a vital role in lean manufacturing processes, allowing companies to eliminate waste and become more responsive to customer needs.
What are the Challenges of Changeover with Packaging Machines?
In brief word, the challenges of the changeover with packaging machines can be included in a single one: minimize downtime and achieve maximum productivity, and take maximum avail of the machine’s capacity. In the following part, however, we will explain still all the facts about it.
Redundant of parts and components for the changeover
The traditional way of the changeover with packaging machines is tedious and involves replacing many parts and components.
Old-fashioned packaging equipment is usually not designed and built with concerns around the flexibility of fast and efficient changeover.
Because the focus at the time of their design was on high-volume production, where speed and efficiency in producing large quantities of a single product took precedence over flexibility and adaptability to frequent product changes.
Another reason is that in the past, companies are not as active as they are nowadays in designing unique packaging styles, or say, things were more standard. Once a product is launched, the packaging will remain the same for many years.
A peek at our old model of cartoner
ELITER Packaging Machinery
The result is that the machine is built with parts and components specifically made for the packaging of the original products for which the machine was designed. And to do the size and format changeover requires a tedious process to replace all of them.
Repeatability is not guaranteed
Old-fashioned packaging machines typically rely on manual adjustments and mechanical components that are not designed for quick and precise changes in size. Or say, it is primarily “experience-based”.
While human beings are born to inevitably make mistakes, counting on “experience” is not completely safe to ensure that the technicians can replicate the size changeover every time without committing mistakes or wasting time struggling with setting and configuring the machines.
Recruiting and retaining skilled workers
The “experience-based” changeover process with old-fashioned packaging equipment requires that food processing and manufacturing companies and co-packers have a team of skilled mechanists and technicians to carry out the process. While one may have acquired skills with the task on a specific model of cartoning machines, the experience may not apply to a cartoner by another manufacturer. The same problem happens between different packaging machines such as between a tray sealer and a thermoforming machine.
For the production side, it is difficult to find the right technician, while for the technician, the experience is not of significant value now that it will not benefit their career, and neither can it be applied to their future jobs.
Minimizing Downtime and avoiding loss in production
Downtime is one of the biggest challenges faced by manufacturers during changeovers. When a machine has to be adjusted, reconfigured, or cleaned, production comes to a halt. This can lead to lost revenue and decreased efficiency. Depending on the complexity of the equipment and the extent of the changes needed, downtime can last from some 15 minutes to even an hour.
A co-packing company may have to do multiple size and format changeovers on a single set of packaging equipment during a shift. Imagine that it takes 30 minutes to do the changeover and there are 3 products in different packaging sizes and formats to automate, the shift will lose some 1.5 hours due to the changeover which stands for decreased efficiency and revenue.
What are the recent technologies that can facilitate the changeover with packaging machines?
PMMI’s Top to Top report highlights that industry-leading changeovers require multi-functional packaging equipment with modular components, easy operator use, safety and hygiene considerations, and increased reliability and efficiency. The biggest concerns reported by CPG manufacturers for easy and fast changeovers include recruiting and retaining top talent, uncomplicated machinery, flexible packaging lines, and easy and effective cleaning and sanitization of equipment.
Original Equipment Manufacturers (OEMs) are now constantly looking into solutions to meet the final user’s expectations regarding fast size and format changeover, and among the solutions, they offer there are primarily:
Quick-release components
One of the most significant developments in changeover technology is the use of quick-release components. These components allow operators to quickly and easily remove sections of machinery that are specific to each product or package type. Replacing these parts with pre-configured components that are designed to work with the new product reduces downtime and increases productivity. The use of quick-release components also simplifies the cleaning process, making it easier to maintain hygiene standards between product runs.
Quick Release Smart Conveyor by ELITER Packaging Machinery
Modular designs
Modular designs allow manufacturers to customize their packaging machines to meet specific product requirements. This involves dividing the machine into modules, each of which can be easily replaced or modified to suit the needs of different products. For example, a modular design may allow for the addition of an extra filling station, a modified nozzle, or a different packaging material. This flexibility makes the changeover process more efficient and cost-effective, as there is no need to invest in separate machinery for each product.
Automated changeovers
Automated changeovers involve the use of robotics and other automated systems to quickly switch between different products. This technology eliminates the need for manual intervention, reducing the risk of human error and speeding up the changeover process. It also allows manufacturers to increase production speed and output while maintaining consistent quality and accuracy.
Digital connectivity
Remote Control
Source: Packaging Digest
Digital connectivity enables manufacturers to monitor and control their packaging machines remotely. This technology allows operators to identify and diagnose any issues that may arise during the changeover process quickly. Additionally, it allows manufacturers to track production data and identify areas for improvement, ultimately reducing downtime and increasing efficiency.
Augmented reality (AR)
Augmented reality technology is increasingly being used in manufacturing industries, including packaging. AR systems use computer-generated images to enhance the operator’s view of the machinery, providing them with additional information and instructions during the changeover process. This technology can help reduce errors and improve accuracy, making the changeover process faster and more efficient.
Accommodate Fast Changeover with Flexible Packaging Equipment by ELITER
ELITER‘s next-generation packaging machines including Cartoner and Wrap-Around Sleever are incorporated with recent technologies of multi-axis servo and motion control to uncomplicate your packaging automation.
Let’s address the advantages of our “Next-Generation” solutions that can fulfill your expectation with flexible packaging:
- Assisted changeover: The multi-axis servo structure lays the foundation that the machine can offer automated and motorized changeover with minimum manual intervention.
- Recipes: You can expect to cover and adop multiple SKUs on a single set of flexible packaging equipment with just a click on HMI to switch between them.
- Tool-free changeover: Our “Next-generation” packaging machines are with incorporated size changeover tools that set you free from spanners or screwdrivers. You can expect a 10~15 minutes changeover time.
Bibliography
- Packaging World. (2019). Why Fast Changeover is Critical to Your Packaging Line. Retrieved from https://www.packworld.com/home/article/21106425/why-fast-changeover-is-critical-to-your-packaging-line
- National Institute of Standards and Technology (NIST). (2005). Quick-Changeover Concepts Applied: Dramatic Results. Retrieved from https://www.nist.gov/publications/quick-changeover-concepts-applied-dramatic-results
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