This article will take an in-depth look at packaging equipment.
What will be covered will include:
Packaging equipment refers to machinery designed to enclose and safeguard products by placing them into containers for purposes such as sale, distribution, shipping, storage, and usage. This machinery plays a crucial role in the marketing process by ensuring that products are presented with the appropriate image and design. Essentially, packaging equipment streamlines and accelerates the process of encasing products in protective containers or wraps.
The packaging process is essential for protecting products and providing crucial information on their use. Packaging equipment helps to reduce labor costs while boosting efficiency and productivity. This equipment covers various functions, including shrink wrapping, coding and marking, case packing, and sealing, ensuring each step of the packaging process is carried out effectively and economically.
Given the vast array of products, packages, materials, and goods available, a diverse range of packaging equipment is necessary to address different needs. It is impractical to rely on a single type of packaging equipment for all products, leading to the development of specialized machines tailored to specific packaging functions.
The various types of packaging machines include strapping machines, pallet wrappers, carton and container sealers, and industrial scales. Also included are sorting, counting, and accumulating machines as well as machines that close and seal products with glue, caps, corks, heat seal, and other methods.
Packaging equipment comes in various specialized forms, making it challenging to categorize them into a single group. Each type of packaging requirement is met with distinct machinery, and some machines are designed for specific, unique applications.
Accumulators are used to collect items, while batching machines prepare products for further processing or packaging. Additionally, bagging, banding, sleeving, and box-making machines handle different aspects of the packaging process.
Bundling machines arrange items into groups for banding or wrapping, capping machines apply caps, and carton machines produce cartons. Closing machines seal packages, and bottling machines fill bottles, which are then processed by batching machines and wrapped in plastic by wrapping machines before being placed on pallets for additional wrapping.
The complexity of the packaging process is managed efficiently with the use of automated or semi-automated packaging equipment.
Transitioning from manual to semi-automatic and fully automated packaging systems provides various advantages for packagers. Beyond reducing labor costs, automation can enhance quality consistency and improve overall throughput.
Advancements in packaging automation increasingly involve the use of robotics and programmable logic controllers.
Large completely automatic packaging operations can include several parts of major machinery from different manufacturers, also conveyors and ancillary machinery. Joining such systems may be a challenge. Often external engineering firms or consulting firms are utilized to coordinate huge projects.
In the context of packaging, the terms "machinery" and "equipment" are often used interchangeably. However, in this article, "machinery" will specifically denote the machines that perform the packaging tasks, while "equipment" will refer to both the machines and materials involved in the packaging line.
Determining the cost of packaging machinery involves understanding specific needs, the type of machinery required, and any additional selections necessary for particular applications. It is also important to consider incorporating a preventative maintenance plan or engaging a dedicated technician to manage downtime on the customer’s terms.
Given these considerations, packaging machinery costs can vary significantly. This variability arises because each packaging line is unique, with its own set of materials, machinery, energy needs, and geographical factors. Consequently, the costs associated with different packaging lines are rarely the same.
The following discussion will explore the various factors influencing the costs of packaging lines, including the expenses related to purchasing machinery, materials, and other essential components needed for effective operation.
To grasp the cost of packaging machinery, it's crucial to evaluate the following stages:
Next, gaining a clear understanding of the mathematics involved in packaging materials is essential. For example, while the price per roll of shrink film is important, the cost per package is even more crucial. By analyzing the cost of each package, performing calculations, and identifying ways to reduce expenses, you can effectively manage your budget and enhance cost efficiency.
The process starts with calculating the actual usage of film and then progresses to determining the specific cost per package.
To calculate film usage, divide the total film length by the film cut-off length and then subtract the rewrap percentage. For instance, a standard roll of 60-gauge center-folded film measures 4,375 feet (or 52,500 inches). If the film cut-off is 11 inches, dividing the total length by this cut-off yields about 4,772 packages per roll. After accounting for a 3% rewrap percentage, the effective number of packages per roll is approximately 4,629.
Math Equation example:
4,375 feet/roll = 52,500 inches/roll
52,500 ÷ 11 inches of film cut-off = 4,772.73 packages/roll
4,772 × 0.03 re-wrap percentage = 143.16
4,772 - 143.16 = 4,629.57 packages/roll of film
Calculating the cost per package is straightforward: divide the cost of each roll by the number of packages it yields. For example, if a roll of film costs $128 and produces 4,629 packages, divide $128 by 4,629 to find the cost per package. Then, multiply this figure by 1,000 to determine the cost per thousand packages. In this case, the cost comes out to $27.65 per thousand packages.
Math Equation Example:
$128/roll
4,629.57 packages/roll
128 ÷ 4,629.57 = 0.2765
.2765 × 1,000 = $27.65/thousand packages
These calculations provide a concrete estimate of the cost for shrink wrap packaging. To further reduce this cost, consider the following tips.
When discussing with a sales representative, be sure to inquire about rebates, special offers, and additional opportunities that could lower the purchasing cost. Given the significant investment required for packaging machines, there may be several ways to negotiate a better price.
When purchasing packaging machinery, it’s common to receive offers from various sales representatives. It’s important to ask detailed questions about the base machinery and the specific options required to package your products effectively. Contacting multiple manufacturers for quotes can help you compare prices and find the best deal.
Occasionally, a quote from one company might be significantly lower than those from competitors, even if the machinery appears similar. It’s worth exploring different vendors to uncover these potential savings.
Sometimes, customers pay a premium for well-known brand names, but this doesn’t always guarantee the best performance. Lesser-known brands might offer more effective machinery at a lower cost. Evaluating the performance and value of the equipment, rather than just the brand, can lead to better packaging solutions.
When buying and operating packaging machines, there are numerous factors to consider, and there's no one-size-fits-all solution for every business. Some aspects of purchasing and using packaging machinery offer only two distinct options, where one may be suitable for one business but not for another. These considerations include:
Implementing a preventative maintenance plan is an additional expense when acquiring packaging machinery, but it can lead to significant savings in the long run. Regular maintenance helps prevent component wear and potential failures that could cause costly downtime and repairs. By staying proactive with maintenance, you can minimize the risk of severe damage and maintain smooth operations.
Failure of a damaged component can potentially lead to further damage to other parts of the equipment or even pose a risk to employee safety. A robust preventative maintenance strategy will greatly minimize downtime, ensure that machinery operates at its best, and facilitate prompt repair and service when needed.
Choosing an alternative formulation for packaging materials can lower costs associated with the machinery that handles them, such as shrink wrap and stretch wrapping equipment. Many companies overlook the fact that there are often multiple material options that can effectively package a given product.
Getting assessments from representatives of various vendors on your current packaging lines can offer valuable insights into your existing packaging processes, including the materials, equipment, and procedures in use. This information helps both your company and the representatives identify opportunities to optimize current practices before investing in new machinery.
Packaging is crucial for safeguarding products, and today it is largely accomplished using specialized machinery. These machines are increasingly important and perform several key functions, including:
This section will explore the various kinds of packaging machinery and equipment that are utilized.
The different types of packaging machinery are:
Filling machines or fillers are utilized for packaging, mostly for beverage and food but for other products also. These are used to fill either a pouch or a bottle, depending on the product. The following are the most popular.
Augers and agitator fillers are designed for dispensing dry powders such as flour and sugar. These fillers feature a cone-shaped hopper that stores the powder and uses an auger conveyor, managed by the agitator, to transfer it into pouches.
The powder is placed into a pouch, typically made from poly or paper, which is formed using a collar. The pouch is then sealed through a series of dies and heaters. The interface where the powder is applied plays a crucial role in ensuring effective filling.
These systems provide a combination of speed, flexibility, and precision for linear feeders. Each weighing hopper is designed to meet the demands for accurate measurement.
Designed for handling oils, liquids, and thin edible products, these fillers operate by filling containers like tubs or bottles that are fed into the machine. After filling, the open bottles are transferred to another conveyor system for sealing.
These fillers are designed for products that are counted by units rather than weight. They are suitable for small bottles, similar to other flow fillers. The hopper is configured to enable the counting of individual items such as candy pieces or tablets through scanning.
Positive displacement pump filling machines are versatile, managing various container sizes, fill volumes, and product types. Initially designed for gels, lotions, and creams, these fillers are also suitable for water-like liquids and thin pastes.
This machinery efficiently handles a range of products, including thick sauces, cosmetic creams, hair conditioners, viscous shampoos, honey, paste cleaners, hair gels, and car wax.
Vertical form fill seal machinery is an automated packaging system commonly used in the food industry, as well as for various other products. This machine converts flat film rolls into stand-up pouches and plastic bags while simultaneously filling and sealing them. It is capable of packaging both liquid and solid products.
The machine operates with a continuous roll of flat plastic film, which may have labels and artwork applied either on the inside or outside. While plastic is the predominant material used in food packaging, the machine can also be adapted to process metalized paper, film/foil, and fabric by modifying the edge seaming and sealing techniques. For other products, the film might undergo a sterilizing chemical wash and drying process before being used in the packaging system.
Cartoning machinery, also known as a cartoner, is designed to create cartons by folding, erecting, sealing, and side-seaming them. This equipment converts flat carton board blanks into fully assembled cartons that can be filled with products or bags. After filling, the machine uses slots or tabs to apply adhesive and completely seal both ends of the cartons.
Cartoning machines can be categorized into two main types:
One type of cartoning machine picks individual folded cartons from stacks, erects them, and fills them with products or bags of products through the open ends. The cartons are then closed by tucking in the end flaps or applying adhesive or glue. Products can be inserted using pressurized air or mechanical sleeves, or manually in some cases. This type of machinery is commonly used for packaging items such as confectionery, food products, pharmaceuticals, miscellaneous goods, and cosmetics.
Pallet wrappers are widely used in packaging lines around the world. They offer significant cost savings compared to manual wrapping, leveraging the stretch capabilities of stretch film to ensure both time and cost efficiency.
A stretch wrapper helps ensure that exact load containment for wrapping operation is being used. For load containment, three variables are considered:
This machine operates by placing a pallet on a rotating turntable. As the turntable spins, a wrap application system wraps the stretch film around the load, typically starting at the bottom and moving up to the top before returning to the bottom.
Turntable wrappers are among the most commonly used stretch wrapping machines and can be configured to efficiently handle a variety of applications.
In straddle wrappers, the load remains stationary while the wrap application system rotates around it. This type of wrapper is effective for wrapping both lightweight and heavy, unstable loads and can handle a range of volumes from low to high.
Orbital wrappers, sometimes called "ringer" wrappers, wrap the pallet by moving under and over the load as it progresses through the machine on a conveyor. These wrappers are particularly useful for packaging irregularly shaped or flat products, such as rolled carpets, pipes, and windows.
These high-speed wrappers can typically handle up to 200 loads per hour and are commonly used in the beverage and toiletry industries. Although highly specialized, they represent a small fraction of the stretch wrapping machinery currently in operation.
In these machines, the load remains stationary while the wrapping system rotates around the pallet.
A shrink tunnel is a key component in many packaging lines. When set to the appropriate temperature, it effectively shrinks a shrink film around a product. The process involves passing a product wrapped in shrink film through a hot tunnel, which causes the heat-sensitive film to contract uniformly around the item.
Airflow within the machinery prevents the products from overheating. For items that are particularly heat-sensitive, special heat-sensing tapes are used to determine if the product is suitable for packaging with a heat tunnel.
If the tapes indicate that the heat tunnel is not suitable for the product, packaging professionals can suggest alternative packaging methods.
These machines encase products in a plastic shell, which is supported by either a blister board or another plastic piece. The three main types of carded packaging are skin packs, blister packs, and clamshells. Skin packs and blister packs feature plastic shells with blister board backers, while clamshells are entirely made of plastic and close like their namesake shellfish.
Carded packaging options such as skin packs, blister packs, and clamshells offer both protection and visual appeal that might not be achieved otherwise. Blister packs are commonly used for fishing lures as they protect the hooks while providing a clear view of the product inside.
Skin packaging is particularly effective for tools like wrenches, pliers, screwdrivers, and hammers. Because skin packs conform to the shape of the product, they allow potential customers to examine the contents closely and securely hold the item in place.
These machines are available in both semi-automatic and automatic models. They feature rotating sections that keep the plastic part of the blister pack securely in place.
As the machinery rotates, empty plastic shells are filled with the product either automatically or manually. After filling, blister board backers are attached to the back of the plastic shells using glue, either by machine or by hand, completing the blister pack.
Although blister packs and skin packs are similar, the machinery used to produce them differs significantly. Skin pack machinery features a platform for supporting the backing substrate or blister board, onto which the products are placed before packaging.
The machine applies a heated, soft plastic layer that molds over the products. Vacuum sealing is commonly used to ensure a snug fit. The substrate then adheres to the heat-sealed layer on the cardboard.
Blister packs and clamshell packs differ significantly. Clamshells are made from a single piece of molded plastic with a hinge. They can be sealed using various methods, including staples, press-fit closures, buttons, RF sealing, or heat.
Clamshell machines feature an automatic lid-closing mechanism, which, while efficient, requires a considerable amount of space.
These machines are used to erect or unfold cardboard boxes for product filling. They come in manual, automatic, and semi-automatic types. In manual machines, an operator unfolds the box, folds it, and tapes the flaps either by hand or with a taping machine. Once prepared, the box is either passed to the next worker or moved along a conveyor.
Semi-automatic erectors handle the second and third stages of the process automatically. A conveyor machine guides the box through areas that shape it accurately. Once erected, the box is conveyed to a stack either by another conveyor or by hand.
An automatic case erector employs mechanical components, such as a robotic arm, to retrieve a box from the pile, unfold it, and place it onto an automatic conveyor. The box then travels through the conveyor, gets filled with products, and is sealed either manually or by automated mechanisms.
The different types of packaging equipment include:
CO2 lasers, in particular, are highly efficient for processing packaging materials such as paper, cardboard, wood and its derivatives, as well as plastics and their derivatives.
The laser beam vaporizes material along a defined path, with the quality of the cut varying depending on the material. CO2 laser cuts produce clean edges on many surfaces, often eliminating the need for additional finishing and making the final piece ready for use.
Laser cutting is used to create openings and windows in packages, add features such as easy-to-open tabs and tear openings, design filtering systems, and cut parts of packages for assembly at a later stage.
Laser engraving and marking both use lasers to imprint marks on materials, though the processes differ slightly. Laser marking involves a superficial change to the material, resulting in a permanent but decolorized mark. In contrast, laser engraving involves a deeper transformation, creating a more pronounced and tactile inscription on the material.
Lasers enable manufacturers to engrave logos with exceptional detail, providing a permanent mark. They can also be used to print production batches or expiry dates directly onto packaging.
A label is a piece of plastic film, paper, metal, cloth, or other material attached to a product or container, on which is printed or written symbols or information about the product. Packaging might have labeling affixed to or integrated with the package.
These labels can display a range of information including barcodes, pricing, UPC codes, usage instructions, advertising, addresses, and recipes. They can also be used to help prevent pilferage or tampering.
A pallet is a flat platform used to support and stabilize packages during lifting with equipment such as pallet jacks, forklifts, front loaders, cranes, or jacking devices. It forms the structural foundation for unit loads, enhancing storage and handling efficiency. Goods or shipping containers are often placed on pallets and secured with stretch wrap, strapping, or shrink wrap before being shipped.
Pallets are highly compatible with contemporary packaging solutions, including intermodal containers and corrugated boxes commonly used for bulk shipping. Although many pallets are made of wood, they can also be constructed from paper, plastic, metal, or recycled materials.
Marking refers to the identification, description, instructions, warnings, specifications, weight, or UN markings required on the external packaging of dangerous materials or hazardous goods. It serves the same purpose as labeling.
A collaborative robot is a double or single robotic arm which can be trained to imitate motions or gestures. These robots repeat the operation over and over again. Some of these robots improve on the trained gestures. After learning from repeating motions, they learn to carry out better work.
These robots are equipped with safety features, including sensors that detect when a human enters a collaborative area. In such cases, the robot slows down or stops completely. Once the human leaves the area, the robot resumes its tasks. Many companies use collaborative robots in packaging to improve efficiency and help get products onto store shelves.
Packaging suction cups are used to move and position a variety of packaged materials. When pressed against a container, they create a vacuum that grips the container, allowing it to be lifted by a robotic or mechanical arm. These suction cups work with lifting devices programmed to transfer materials from one location to another.
The design of packaging suction cups allows them to lift materials even if their surfaces are oily or damp. Various types, such as flat concave, bellows, and long bellows suction cups with extended thin lips, are effective for handling corrugated cardboard and boxes.
Packaging suction cups are made from a range of materials, including nitrile, neoprene, polyurethane, silicone, Viton, vinyl, and natural rubber. Natural rubber is particularly suitable for gripping, pulling, and feeding items.
Types of packaging suction cups include:
The five suction cup types mentioned above are among the most commonly used for packaging. For specialized or unique packaging materials, manufacturers can design and engineer custom suction cups to suit specific applications. The popularity of packaging suction cups is attributed to their gentle, smooth, and efficient handling of packaged materials.
This chapter will cover the factors to consider when purchasing packaging equipment, along with an overview of its applications and benefits.
A summary of considerations when purchasing packaging equipment are:
These considerations can be further elaborated and discussed as follows:
Going directly to the manufacturer is a common choice because they have in-depth knowledge of their machinery and can answer detailed questions from customers.
However, it's important to recognize that manufacturers may be biased when discussing the best brands or services. Both OEMs and distributors have their advantages and disadvantages, covering aspects such as cost, customer service, and repair quality.
Depending on factors such as location, budget, and existing infrastructure, distributors may or may not be the best choice for your company.
Selecting packaging machinery involves numerous considerations, with the type of materials being among the most crucial.
In addition to equipment and materials, the operational environment is also a critical factor. Working with a distributor offers access to a wide range of options and provides valuable guidance, advice, and product acquisition support.
Extreme temperatures, whether very cold or very hot, must be managed with appropriate cooling or heating systems. It is essential to ensure that these systems are correctly installed and functioning to handle the environmental conditions.
No customer wants to deal with pneumatic machinery. Not only is pneumatic equipment outdated, but it is also environmentally unfriendly due to its high electricity consumption.
Many modern machines have eliminated pneumatic components, leading to significant cost savings because compressed air is an expensive utility in a plant.
By removing pneumatic parts, companies can reduce expenses related to replacing and disposing of worn-out air cylinders. Additionally, some machinery incorporates "lean technology" to eliminate film breaks, reducing the need for re-wrapping loads and minimizing material waste. Typically, lean technology machinery uses fewer materials and features precise film delivery systems.
Considering eco-friendly materials is also important. While many metals used in packaging machines can be recycled, some materials cannot be recycled or are not typically recycled.
Based on the types of machinery in use and the layout of equipment, it is advisable to plan the strategic movement of equipment at the right times. Factors such as volume, electrical requirements, placement in the line, and machinery weight make early planning a crucial part of this process.
To ensure a smooth and efficient installation, certain machinery should be installed in a specific sequence according to the flow of the packaging line. It is essential for a technical service contact or company to determine the order in which machinery should be moved.
Purchasing machinery is a significant investment for many businesses, and buyers often feel uncertain or uninformed about the process. One key decision is whether to buy or lease the machinery. Neither option is universally suitable; each has its advantages and disadvantages, and the choice may depend on specific line dynamics and applications.
Considerations that will help determine the best option for a packaging line include:
It is crucial to research and evaluate at least three suppliers, considering several important factors for each.
Location – Choosing a packaging machine supplier close to your company's location can facilitate quicker response times for emergency services or repairs.
Technicians – Ensure that the supplier employs certified and experienced technicians who are trained to work with packaging equipment.
Customer Service – While it might be tempting to choose the cheapest option to cut costs, selecting a supplier with poor customer service can negate the savings. Poor service often leads to additional expenses.
Cost – Compare the cost and quality of materials, as lower-cost films might have less clarity, while higher-cost films offer better clarity and performance.
Parts – The frequency of machinery use will affect downtime due to repairs or emergency services. Inquire about parts availability, lead times, and preventative maintenance schedules to minimize disruptions.
Packaging equipment is used in various applications, including:
Food – Ready-to-eat meals, grains and seeds, milk and liquids, spices, coffee, sugar, oil, salt, tea, bakery products, beverages, candy and confections, dairy products, and bakery items.
Pharmacy – Tablets, capsules, granulated products, oral liquid dosages, ophthalmic and ENT solutions, injectables, gels, and oral dosage powders.
Others – Agrochemicals, adhesives, fertilizers, lubricating oils, coolants, varnishes, paint powders, pet foods, hardware, cement and wall putty, pigments and dyes, foundry materials, inoculants, and flux.
Packaging equipment offers several advantages, including:
Production – A comprehensive packaging line can significantly influence a company's success, particularly when handling large quantities of products quickly. Although the initial investment in such machinery can be substantial, it is often justified by the efficiency and quality improvements it brings over time.
Total Cost of Ownership – One of the key factors to evaluate is the total cost of ownership. Effective packaging machines can reduce the need for a large workforce, leading to lower labor costs. Despite their high purchase price, when compared to manual labor, automated machinery often proves to be a more cost-effective solution in the long run.
Speed – Automated packaging systems can process a higher number of packages per hour compared to manual methods. For businesses where rapid product delivery is crucial, having efficient packaging machinery is essential for maintaining competitive advantage.
Reliability – Unlike human workers, packaging machines do not require personal time off, sick leave, or vacations. While occasional mechanical failures may occur, these can typically be addressed with routine maintenance. This reliability helps prevent costly downtime and inefficiencies, ultimately saving both time and money.
Some of the disadvantages of packaging equipment include:
Cost – The addition of packaging can significantly increase production expenses and, consequently, the retail price of products. In certain sectors, such as cosmetics, packaging can account for up to 40% of the product's final selling price. Developing new packaging solutions can also be expensive, impacting the overall product cost.
Landfill Impact – Packaging contributes heavily to waste production. In the USA, it is responsible for approximately one-third of municipal waste. Although some packaging materials can be recycled, many cannot. For instance, recycled plastics are often not used for food packaging, despite their origins. As a result, a substantial portion of packaging waste ends up in landfills.
Production Footprint – Increased packaging results in higher resource consumption. For example, the production of shopping bags in the USA consumes around 12 million barrels of oil annually, while over 10 million barrels are used for manufacturing water bottles. The production process also requires energy, often derived from fossil fuels, and can contribute to water and air pollution.
Packing equipment is pertinent in every industry because it has the ability to influence the production cost of given products in the business. The more competent the packing machines are, the less costly the production is sustained and the higher the number of sales done for that given product.
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