Adapting to increased demand as your business grows is essential for safeguarding your success. Packaging automation can significantly impact your production capabilities and profit margins, but understanding your options and how to get started can be challenging. In this guide, we will help you understand when it makes sense to implement packaging line automation, as well as the types of automation available and how they work.
Deciding to invest in new technology is a big decision for any business. If you’re exploring your options, the following considerations will illustrate when it’s most essential to introduce automation to your packaging line.
Review your target market and projected growth potential. If you’re adding new products in the near future or anticipating large amounts of growth, automation can help you keep up with demand. Determine what your packages-per-minute (PPM) currently is and consider what you expect your output to be over the next 12-24 months.
When researching packaging automation, a business’s labor force is one of the first areas that should be reviewed. Automation is particularly beneficial in situations such as:
If these situations are directly related to your packaging processes, automation can decrease repetitive strain injuries and worker compensation claims, and reduce the need for investing in improved ergonomics.
When your workforce performs repetitive tasks, they are more likely to experience injuries and feel unfulfilled. Introducing automation not only improves your production speed but also allows your employees to focus on more rewarding tasks. One example of this is using a case erector to form the boxes your products are shipped in. Automatic and semi-automatic case erectors operate quickly and effectively, boosting packaging productivity.
No matter how well-trained your team is, when manual labor is used in packaging lines there will be an increased amount of waste material and damaged products. To minimize these issues, solutions like stretch wrap machines and case sealers consistently use the right amount of product to protect your shipments.
If you produce multiple types of items, facilitating product changeovers can be time-consuming, even requiring as much as 4 to 8 hours to complete. Automation reduces the time needed to perform these tasks.
Now that you know some scenarios in which automation would be most helpful, let’s explore the various packaging line automation types. Automated technology can be categorized into three types:
For many businesses, the best automation solution is not only one type of technology but rather a combination of multiple types.
When you’re beginning the process of implementing packaging automation, determining your needs and planning carefully is crucial. The best way to accomplish this is by selecting the right automation partner. TPC has nearly 60 years of industry experience and has helped thousands of customers adopt innovative automation solutions.
When you partner with us, we will guide you through the entire process and ensure you obtain the ideal solution for your needs. If you’re starting your project, some initial considerations you can begin with include:
Our team has brought the most advanced packaging automation technology to many demanding industries. We take the time to understand your needs and can help you plan a successful automation project.
Investing in packaging line automation can deliver numerous advantages for your business:
Whether you’re dealing with an inability to meet demand, a challenging labor market, or workplace safety issues, TPC can help you find an automated solution that delivers the benefits you’re looking for.
At TPC Packaging Solutions, we offer automation technology for every stage of the packaging process. From entry-level packaging automation to complete turnkey systems, we provide optimized solutions tailored to your business’s unique needs. We also provide ROI statements to help you understand how quickly your new equipment will pay for itself. To learn more about our packaging line automation solutions, contact our team today.
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Packaging keeps products safe and makes them look attractive. Although it is the final step in your production line, it is the first thing your customers see. So, it needs to be attractive and consistent to be effective.
Manual packaging can be time-consuming and cause employee fatigue. Further, it may lead to a waste of packaging material and inconsistency. Moreover, it may not be cost-effective.
Packaging automation is using automatic or semi-automatic machinery at various stages of the packaging process, such as filling, wrapping, labeling and palletizing. Almost all industries can benefit from packaging automation equipment, especially since material handling can be challenging in this age of rising ecommerce.
Many types of packaging machinery, including wrappers and palletizers, are available these days. You can use any of those, depending on your products’ specifications.
Whichever automated packaging machinery you choose, you can be assured of many or all of the following advantages.
Quality: Automated systems are accurate and consistent because they have precise, standardized settings. They help improve product quality, cycle time and operations in general.
Productivity: Manually packaging pallets, boxes and other products can be difficult and time-consuming. Your workers may become tired from the repetitive, monotonous and strenuous activity. Machines can work much longer at full efficiency. They also offer much higher speeds.
Product care: If you use the right machinery, your products can be securely packaged. For example, a good stretch wrapping machine will ensure that the products are well-wrapped and safe from contamination. This increases the durability and shelf life of products.
Employee safety: Studies show that 20 percent of forklift accidents are caused when people walk on warehouse floors. Similarly, manual wrapping and palletizing can cause cuts, tears and back injuries. By introducing automated packaging systems, you can make your warehouses safer. You can ensure that your operators remain on the forklifts and also avoid other injuries.
Expenses: Although it may seem expensive, the benefits of automation include recovering the costs in a matter of months. You may also be eligible for tax benefits, such as the write-offs and depreciation under Section 179 of the Tax Cuts and Job Act of .
Automated packing ushers in increased productivity. Machinery can perform more tasks in less time than your employees. This saves time and labor costs. You can also save on packaging material and storage space, thus, making shipping and handling more cost-effective.
Many automated processes have a self-vacuuming function to remove dust and dirt in the machines. This means there is no real need for costly maintenance.
Low wastage: Machines are economical in using packaging material. They cut the material precisely and maximize its use by using well-defined patterns. This streamlines the packaging process and reduces waste of materials.
Sustainability: Many original equipment manufacturers (OEMs) now manufacture packaging machinery with sustainability in mind. Such machinery not only offers good return on investment (ROI), but also is beneficial for the environment. They use fewer materials and have lesser greenhouse gas emissions.
Specialized packaging: If you have many products and different packaging sizes, a semi-automated solution would suit you better than a wholly automated one. Regardless of how diverse your products are, you can find suitable packaging machinery for it. Moreover, by automating packaging, you can change the outline for a case or pallet quickly.
Customer confidence: People buy products if they are pleasing to the eye. One of the other advantages of automation is having packaging with accurate information. This creates a good impression and helps promote the brand. Moreover, consumers are able to keep machine-wrapped products much longer than by refrigeration alone. This increases the demand for items packed by machinery.
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