5 Tips for the Integration of Automated Packaging Systems

“I need my production to be fully automated…”

Anyone looking to save production costs by implementing packaging automation or who may have already some equipment in their facility may expect further than a standalone packaging machine and forge ahead to integrate some more machines to connect with their existing equipment.

Connection of your existing packaging equipment with additional machines is not a simple calculation of A plus B but a systematical engineering process that requires step-by-step planification and then a certain level of technical expertise. In some circumstances, the integration of packaging systems would be a challenge for even a specialized packaging automation company, not even to mention how complex it will be for a company that is merely the final user with the capability of engineering of packaging automation.

Sounds DAUNTING? 

Not necessarily so. In this article, we should provide some tips for your regarding how to integrate several packaging systems and equipment into an automated line.

Assess your Existing Packaging Equipment

The first step that will pave the foundation for the successful integration project is to assess from all metrics the existing packaging equipment so that the engineering professionals can think of the possible and feasible solutions to connect it to the machines to be installed. The integration of packaging systems involves a lot of detailed studies and reviews including the synchronization, connection for outflow and inflow, coordination of speed, etc. While for each piece of equipment to be integrated into the line they should be assessed for all the metrics listed hereby.

One of the basic concerns is the compatibility Every packaging line and system has specific technical requirements, such as power supply, dimensions, and operating speed. By thoroughly assessing the existing equipment, businesses can determine if it aligns with the desired packaging systems. This evaluation ensures a seamless integration process, minimizes technical issues, and avoids costly delays in production.

Then comes the workflow. Efficient workflow and seamless material flow are essential for a successful packaging line.  Sometimes a packaging machine like a VFFS of either single or multiple lanes is not able to organize in an ordered manner the produced bags or flow packs and its integration will need some additional connection devices like a bag unscrambler or even a delta robot so that the output can be arranged in a timed and regular flow of materials for the convenience of the operation of the downstream machinery.

Assess your Facility’s Space Availability

Reasonable utilization of your facility’s space is the key factor for your long-term productivity. The concerns are as follows:

• The integrated packaging system to be implemented should reasonably take up your current space without too much waste
• Make the current line as compact as possible to improve productivity per area
• Considering also space for entrance and maintenance
• Your space needs to implement also more lines in the further
• …

Your productivity can be rated by diving output by the area. The area is

• either the total space of your facility to assess how efficiently you are using your space

$$ \text{Productivity per area} = \frac {\text{Output}} {\text{Total Facility Space}} \qquad (1) $$

• or the space that the packaging line takes over to assess the effectiveness and productivity of such an integrated line.

$$ \text{Productivity per area} = \frac {\text{Output}} {\text{Sapce of the Line}} \qquad (2) $$

To calculate the productivity of your packaging line in terms of space availability, you can follow the steps below:

• Measure Space Utilization: Measure the total space occupied by your packaging line, including the machines, equipment, workstations, aisles, and any other areas directly related to the packaging process. This measurement should give you the total space utilized by the packaging line.
• Define Output Units: Determine the output units for your packaging line productivity calculations. It could be the number of finished products, the number of packages, the weight or volume of packaged goods, or any other unit that represents the output of the packaging line.
• Measure Output: Record the total output of your packaging line within a specific time period. This could be an hour, a shift, a day, or any other duration you choose for analysis. Make sure to count all the finished products or packages that were successfully produced and packaged during that time frame.
• Calculate Space Utilization: Apply the above formulas
• Analyze and Interpret: Analyze the calculated space utilization metric to assess the productivity of your packaging line in terms of space availability. A higher space utilization indicates efficient utilization of available space, whereas a lower space utilization may suggest that there is potential for optimizing the use of space to achieve higher productivity.
• Identify Opportunities for Improvement: Based on the space utilization metric, evaluate the packaging line layout, equipment placement, and workflow to identify any areas with significant potential for improvement. Consider factors such as rearranging machines or workstations, optimizing material flow, or implementing space-saving measures to enhance productivity while utilizing the available space more efficiently.
• Implement Improvements and Monitor Progress: Implement the identified improvements and changes to the packaging line based on the analysis. Monitor the impact of these changes on the space utilization and overall productivity of the packaging line. This will help you assess the effectiveness of the implemented measures and make further adjustments if necessary.

The mindset with this tip is data-based production management that provides analyzable and intuitive insight into the effectiveness and efficiency of your packaging systems.

Advanced Statistical Analysis Tools for Packaging Process Capability
Credit: ELITER Packaging Machinery

Study into the Types of Automation to be Adopted

We once discussed the types of industrial automation and looked into their differences as well as the pros and cons. To review briefly they are:

• Fixed Automation: Fixed automation is usually adopted for only a specific task and how its process and logic are designed in a fixed and repeated manner only for the mentioned task. While fixed automation is specialized in a certain workflow, it is not capable of automating any other process with even the slightest difference.
• Flexible Automation: Flexible automation combines the benefits of fixed and programmable automation by using robotic systems and computer control technology to perform a broad range of tasks in a flexible manner.
• Programmable Automation: Programmable automation involves the use of programmable logic controllers (PLCs) to control and automate manufacturing processes. This type of automation allows for more flexibility as the PLCs can be reprogrammed to perform different tasks or adapt to changes in product specifications.

The integration of packaging systems engages one or several of the above-mentioned automation and the examples of them may be conveyors, pick and place robots, grouping and stacking systems, etc. Working with the OEM to look into the right option can not only improve the efficiency and flexibility for the current purpose your packaging systems are integrated for but as well to take into consideration your potential and future demands so that afterward the costs of upgrading and refitting can be saved.

Speed up Downstream to Make Full Use of your Upstream Output

The throughput of an integrated packaging system depends on how fast the downstream can handle the inflow of packages of materials.

The throughput of an integrated packaging system refers to the rate at which packages or materials can be processed and moved through the system, while the downstream refers to the subsequent stages or equipment in the packaging process that receive the packages or materials from the upstream and continue their processing. It is usually the end-of-line equipment that determines the overall output of the integrated packaging system.

Imagine that you are running a powder-in-bag packaging line where there is an 8-lane vertical packaging machine (VFFS) that runs at a speed of 60 cycles per minute, while each one of these bags should be packed into cartons. Congestion will be caused along the packaging line if the cartoner machine is not able to proceed with such a quantity of inflow. That is the reason why downstream packaging equipment plays an essential role for the integration. To be specific:

The downstream packaging equipment may be the bottleneck

If the downstream stages or equipment cannot handle the incoming packages or materials quickly enough, it creates a bottleneck in the system. This leads to congestion, delays, and reduced throughput. Ensuring that the downstream can handle the inflow efficiently helps prevent these bottlenecks and maintains a smooth flow of materials through the packaging system.

They are related to the overall capacity optimization

The speed of the downstream has a direct impact on the overall production capacity of the packaging system. By maximizing the throughput of downstream, manufacturers can achieve higher production rates and meet customer demands more effectively. It allows for increased output and optimized resource utilization.

Count on a Reliable Manufacturer or Service Provider

A guy who is outsourcing for the client who will be the end user of packaging equipment would usually commit the mistake of sending mountains of inquiries to all of those companies he or she may find on Google, Alibaba, Made-in-China and then picking up several of them who offers the lowest price for the final tournament. Something neglected here with this strategy is that the attention has only been attached to the price while the expertise and professionalism are completely overlooked. That is to say, those who offers a cheap price would not necessarily be the real manufacturer but those who resources and resells, neither do they have solid knowledge of engineering.

The key factor here is to make sure you are working with a true manufacturer and OEM or an integration service provider with an engineering background. They may not necessarily have the knowledge and experience with the machine you are looking for, however, their expertise will give a quick shot to the issues and bottlencks of the integration. Counting on a reliable manufacturer or service provider that specializes in manufacturing packaging machines offers several advantages when it comes to packaging line integration. Here’s why and how they can be beneficial:

• Expertise and Knowledge: A real manufacturer of packaging machines typically has extensive expertise and knowledge in their field. They have a deep understanding of packaging processes, equipment functionalities, and relevant industry standards. This knowledge equips them with the capability to accurately assess your packaging requirements and provide suitable solutions for integrating the packaging line.
• Customization and Tailored Solutions: Working with a real manufacturer allows for customization and tailored solutions that meet your specific packaging needs. They can design and manufacture packaging machines and equipment that fit seamlessly into your existing production line, maximizing efficiency and productivity. They have the ability to customize equipment features, capabilities, and automation levels to precisely match your requirements.
• Quality and Reliability: A reliable manufacturer is committed to producing high-quality packaging machines. By choosing a manufacturer that prioritizes quality control, you can ensure that the equipment is durable, reliable, and built to withstand the demands of your packaging operations. High-quality machines minimize downtime, reduce maintenance costs, and increase the overall longevity of the packaging line.
• After-Sales Support and Service: A real manufacturer typically offers comprehensive after-sales support and service. They have a team of trained technicians who can provide technical assistance, carry out maintenance and repairs, and offer troubleshooting guidance. This dedicated support ensures that your packaging line remains operational and minimizes disruptions or downtime.
• Long-term Partnership: Choosing a reliable manufacturer establishes a long-term partnership. They become familiar with your specific packaging needs and become a trusted source for ongoing support, upgrades, and future expansion of your packaging line. This partnership can lead to better communication, collaboration, and a deeper understanding of your unique requirements.

What May ELITER Packaging Machinery Help You?

ELITER Packaging Machinery has gained solid experience in integration, though our category covers only cartoner, film overwarpper and wrap-around sleever and we may not necessarily or actually manufactures some additional equipment the line will consist of. Yet working with ELITER offers bunches of advantages including:

• Honesty and transparency: 
• Save your budget
• Take avail of our expertise

To request your integration proposal, contact us for further information.

FQAs

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