Five reasons to automate your packaging systems | Sewtec

Packaging is required at three stages during the production line. Firstly, primary packaging encloses the naked product within its wrapper or tray packaging to ensure it doesn’t perish.

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This is then followed by secondary packaging, where the primary-packed product is enclosed within a secondary container, such as a plastic bag or cardboard box. The final stage of the packaging process is referred to as tertiary or transit packaging, which sees the second packaging placed into larger containers and loaded onto pallets ahead of being shipped out.

But what are the benefits of having automated packaging solutions in your production line?

1. Streamline production

Packaging automation is built and designed to mirror the movements made during manual packaging, such as picking up items from a conveyor system and placing them in the respective packaging.

However, an automated system means more products can be picked and packed in less time, which enables the whole operation to be streamlined.

2. Robust reliability

Automated packaging systems are created with robustness in mind. A robot arm working within a production line has the capability to work for more than 70,000 hours (which equates to just under eight years) until it requires maintenance.

This means that your production line can run effortlessly and at a high-performance level for a prolonged period, with minimal maintenance, which will enhance your overall operation.

3. Consistency is key

Across all packaging stages, there is a specific format in which the product needs to be packaged. This is important during the secondary and tertiary steps, as incorrect packing could lead to trays and boxes not being efficiently filled, impacting the overall quality of the packaged product.

Automated packaging solutions can help with the consistency of the packaging of products as it reduces human error. For products which need to be stacked, rotated, or nestled in a particular way, the system can be programmed to ensure this is done correctly and the use of multi-axis robots can help reduce the risk of packaging irregularities. This reduces the amount of product that is wasted, aiding your environmental impact, as well as maximising profit margins.

4. Increased flexibility

Opting for a turnkey automated packaging system brings with it the ability to be more flexible with what is being packaged, as well as how it integrates with existing production lines. By operating with a robotic system, one production line can handle different types of products and packaging, depending on the computerised instruction, increasing the flexibility of the system.

5. Upskilling your people

As automation becomes more prevalent in manufacturing and packaging facilities, so does the need to upskill team members to operate the systems themselves. Automation can alleviate the repetitiveness and high physical demand on manual labour, which reduces staff injury, as well as providing an opportunity for specialised training. An automated system therefore benefits twofold – it can increase speed of production and helps improve staff wellbeing and career progression.

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Robotic packaging solutions bring with them a host of benefits to production lines, such as helping improve efficiencies, accuracy, and flexibility. When combined, these benefits deliver a strong return-on-investment and make deploying an automated packaging solution across all stages best for business.

At Sewtec, we create bespoke primary, secondary, and tertiary robotic packaging solutions for products across a range of industries, including food, pharmaceutical, medical, and tobacco.

Nowadays, case packers are available in several styles and offer a variety of features. With today’s operations ranging from wrap around, side load, and top-load versions to those focusing on faster line speeds and specific packaging requirements, there are many components to consider. Below, you’ll find a list of the basics to help you choose the best case packer for your needs.

Case Packing Considerations

#1 Case Packing Type

There are dozens of case types available, but the most common are top load, wraparound, and side load, all of which have special features that address certain needs. The type you need is often dependent on the type of product you have such as, bottled liquids are generally packaged on a regular slotted top load, which has partitions for added protection. On the other hand, wraparound cases work well for non-breakable bottles or containers. Consider the packing strength and weight limit your products require.

#2 Product Type

The type of product you’re packing will largely influence the type of container and case packer required. The top load case packer is commonly used for products in bottles, pouches, and jarred items. This is because it’s easier to have these (sometimes fragile) items placed inside packaging from above. On the other hand, products like bars of soap or boxes of dried pasta are more easily packaged by sliding them in from the side, hence a side-load case packer is ideal. Wraparound packers are routinely used for bulk items such as, #10 metal cans of food. Additionally, bottom load packers are used for outdoor grills, lawn furniture, and so on. Basically, the gentlest mode of packaging a product is always the goal.

#3 Line Speeds

The speed of the conveyor line is an important factor in both processing efficiency and cost. You want the packer you choose to have enough speed to maintain production quota, but the faster machines cost significantly more. Overall, if your case packing needs are 20 cases or less per minute, the robotic packer, side loader, or bottom load packer should be sufficient. The drop packers and wraparound packers are ideal for packing 20-30 cases per minute, and for faster speeds, consider a continuous motion wraparound packer, rotary packer, or soft placement packer.

#4 Weight and Usage

Choosing a machine that can handle production demands is crucial for machine lifespan, production cycle costs, weight limit factors, and hours used. Be sure to check machine specifications before making a decision.

#5 Floor Space

Square footage is premium in business, therefore, take into account the amount of space you have available for a case packer. The widths, lengths, and angles vary greatly from one machine to the next. Plan and measure carefully, consider directional layout, and guarding requirements.

#6 Changeover Options

Overall, the robotic packers are the most flexible in changeover and automation options. In regards to simplicity in switching, drop packers are a good choice, while wraparound packers offer the least amount of options and flexibility. In addition to the above factors, you’ll benefit from doing your own research. Take time to watch demonstrations of the various packers in use. This will help you determine which case packer will best suit your current business needs. Also, when making your decision, consider all the variables including production efficiency, cycle costs, and product lifespan.

While everyone has a budget, the initial investment is only one component in comparison to the big picture, and buying the proper tools upfront will save you money in the long run.

Benefits Of An IPM Case Packer

Bottom line, a case packer from IPM will maintain constant contact with your products for true “positive” placement and control. If you are interested in learning more about our packaging products and solutions, contact us today at (616) 531- for more information or fill out our online form to request a quote.

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