February 03rd

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Everything to know about packaging equipment and machinery

This comprehensive article delves into the world of packaging equipment and provides detailed information on various aspects of the subject.

The article covers:
' The fundamental principles of packaging equipment
' Different types of packaging machinery and equipment
' Key factors to consider when purchasing packaging equipment, their applications, and benefits
' And much more.

Principle of Packaging Equipment

This chapter delves into the workings of packaging equipment and machinery and explains what it is.

What is a Packaging Equipment ?

Packaging equipment forms an integral component of the packaging process, which extends from initial packaging to distribution packaging. The various operations involved in packaging include cleaning, creation, filling, sealing, labeling, combining, overwrapping, and palletizing.

In some sectors, the effectiveness of heat seals is crucial for the safety of the product, necessitating the stringent monitoring of the heat sealing process through established protocols. Industries such as pharmaceuticals, food, and medical necessitate solid seals on packaging, highlighting the importance of reliable packaging machinery.

Packaging processes can be designed to accommodate different shapes and sizes, or for uniform packaging. While manual processes may provide the flexibility to adjust for package variations, automated packaging processes present advantages such as enhanced quality control and production efficiency.

The shift towards automation in packaging often employs robotics and programmable logic controllers. Large-scale automated packaging systems can feature components from multiple manufacturers, along with conveyors and auxiliary machinery. Integrating these systems can be complex and typically involves consulting either engineering or specialized firms.

Costs Associated With Using Packaging Machinery

Determining the cost to operate packing machines relies heavily on specific needs, machinery type, and additional selections to suit particular applications.

Furthermore, establishing a preventative maintenance strategy or accessing a dedicated technician who can manage downtime on the customer's schedule should be factored into the cost estimation for packaging machinery.

The investment for a packaging line varies considerably by manufacturer, with each line possessing its unique set of materials, machinery, energy needs, geographic factors, and operators.

To navigate the costs of packaging machines, consider the following elements:

First step

Questions to Ask :

' What is the primary consideration when thinking of cost?
' o Purchase price?
' o Cost of ownership?
' o Money?

' Is the purchase price more important than the machine's performance?
' o Will this still be the case in 3-5 years?

' How frequently will the machine be used?
' o Twice a week?
' o Daily?

' How efficient are the company's maintenance technicians?

' Is sophisticated equipment needed or are basic controls sufficient?

' Will the equipment operators be stationary or mobile?

' Is it important to be at the forefront of technology, or is it better to let others test it first?

Second step

Determining Film Usage for Packaging Material Cost-Efficiency Accurate comprehension of the calculations involved in packaging materials is pivotal in the industry, such as shrink film. While the cost per roll is significant, the cost per package is even more pertinent, as it directly influences budgeting and savings. The calculation of film usage initiates by dividing the total length of the film by the film cut-off and subtracting the rewrap percentage.

For example, a standard roll of 60-gauge center-folded film spans 4,375 ft or 52,500 inches. With a cut-off point of 11 inches, each roll can yield about 4,772 packages. Factoring in a 3% rewrap percentage, the film can yield approximately 4,629 packages per roll.

Get a quotation

You can contact us to receive a fast and free quotation or read more on How to get effective quotations for case packing equipment here.

How Packaging Equipment Works

Recognizing the Significance of Packaging Machinery In today's landscape, packaging plays a vital role in preserving and safeguarding products.

Therefore, businesses depend on packaging machinery to perform numerous critical tasks. The employment of machinery in packaging comes with various benefits, including:

' Enhancing labor productivity: Certain packaging equipment, like candy packing machines, can drastically raise production rates compared to manual methods.

' Assuring packaging integrity: Machinery usage is beneficial for exports to secure consistent packaging standards.

' Addressing specialized packaging requirements: Machinery can accommodate unique packaging formats, such as inflatable packaging, skin packaging, vacuum packing, and pressure packing.

' Minimizing labor and enhancing working conditions especially for heavy or bulky products.

' Protecting workers against health hazards and environmental contamination: Machinery can remove manual contact with hazardous substances, dust, etc.

' Reducing packaging and storage costs: Compression packaging can be beneficial for loose articles such as tobacco, cotton, linen, and silk.

' Ensuring proper hygiene: By minimizing human contact with food and medicine, machinery helps in maintaining hygiene standards.

Types of Packaging Machinery and Equipment

In this section, we will explore the diverse types of packaging machinery utilized in the industry..

All-in-one sequential monoblock packaging solution :

Integrates overwrapping, packing, case forming, and sealing within a single machine, ideal for high-speed, high-volume production.

Blister Packaging Machines :

Available in both semi-automatic and automatic variants, these machines possess rotating sections that secure the plastic part of the blister pack. The equipment fills empty plastic shells with products either manually or automatically, and then attaches blister board backers to the shells, either by machine or by hand with glue, to finalize the blister pack.

Carded Packaging Machines :

These devices wrap products within a plastic shell against a blister board or another plastic piece. Carded packaging encompasses skin packs, blister packs, and clamshells. Skin packs and blister packs possess plastic shells complemented by blister board backers, while clamshells are purely plastic constructs that close akin to their namesake.
Safety and aesthetic appeal in packaging various goods, such as fishing lures (blister packs) and tools (skin packs), are provided through carded packaging.

Automatic Cartoning Machines :

Also called cartoners, these machines produce, close, fold, erect, seal, and side-seam cartons. They can fill cartons with products or bags of products, seal them by tucking the end flaps or applying adhesive, and can be horizontally or vertically oriented. Cartoning machines are widely utilized for packaging confectionery, food products, medicine, non-food items, cosmetics, etc.

Case Erectors for Cardboard Box Filling :

These devices are designed for erecting or unfolding cardboard boxes meant for product filling. They are available in three types: manual, automatic, and semi-automatic. Manual erectors require human engagement to unfold, fold, and tape the box flaps, either using a taping machine or manually. Once constructed, the box can either be handed to the next worker or moved via a conveyor.

Semi-Automatic Case Erectors for Conveyor Processing :

These machines automatically conduct the second and third stages of the process through a conveyor system, which results in shaping the box appropriately. After assembly, the box is conveyed to a stack through another conveyor or manually.

Automatic Case Erectors with Robotic Arm Technology :

They make use of mechanical systems, such as a robotic arm, to take a box from a pile, unfold it, and position it on an automatic conveyor. The box is then transported through the conveyor, filled with products, and sealed either through simple manual interaction or mechanical methods.

Clamshell Machines for Plastic Packaging :

Clamshells are a single-piece molded plastic with a hinge, differing from blister packs. Clamshells can be sealed through various mechanisms, such as staples, pressed-fit closures, buttons, RF, heat, etc. Clamshell machines feature a self-closing lid, although they necessitate significant space for operation.

Filling Machines for Beverage and Food Packaging :

Fillers are utilized for packaging predominantly liquids and food but also other products. They work to fill either pouches or bottles, depending on the nature of the item. The most widely-used filler types include:

Auger or Agitator Filler for Dry Mix Packaging : Designed for filling dry mixes like flour and sugar, these fillers possess a hopper in a cone form to hold the mix and fill the pouch via an auger conveyor controlled by an agitator. The mix is placed into a pouch constructed of poly or paper, which is subsequently sealed by a set of dies and heaters. The interface with the powder's application is crucial for ensuring efficient filling.

Flow Fillers for Liquid and Edible Product : These devices are meant for oils, liquids, and thin edibles. The machine fills a tub or bottle that moves through the machine, emitting the filled bottle on another conveyor for sealing.

Positive Displacement Pump Filler for Gel, Lotion, and Cream Packaging : These fillers accommodate a variety of container sizes, fill volumes, and product types. Originally crafted for gels, lotions, and creams, they also manage heavy and thin paste items, in addition to water.

Tablet Fillers for Portion-Counted Product Packaging : Designed for products counted by units instead of weight, these fillers cater to small bottles, having a hopper configured for counting pieces through scanning. Products filled by these machines include heavy sauces, cosmetic creams, hair conditioners, thick shampoo, honey, paste cleaners, hair gels, etc.

Vertical Form Fill Sealing Machine : This efficient automated packaging system serves the food sector and beyond. It creates stand-up pouches and plastic bags from a flat film roll, filling the bags with products and sealing them. The film can be composed of multiple materials, including plastic, metalized paper, film/foil, among others. It may also undergo sterilization before being utilized in the machinery.

Vibratory Weigh Fillers : Offering a mix of speed, versatility, and precision for linear feeders, with each weighing hopper designed to ensure accuracy.

Pallet Wrappers or Stretch Wrappers :

Common in numerous packaging lines globally, these machines afford significant cost savings for extensive operations. They employ the stretching capabilities of the stretch film, ensuring accurate load security while concerning the number of layers, wrapping force, and film thickness.

Orbital Wrapper :

Sometimes called the "ringer," it wraps pallets by going under and over the load, making it suitable for packaging uniquely shaped or flat products, such as rolled carpets, pipes, and windows.

Ring Straddle Wrappers :

These fast machines are capable of wrapping up to 200 loads per hour, and are commonly employed in beverage and personal care industries. They stabilize the load while the wrap-applying mechanism rotates around the pallet, allowing for wrapping of unstable loads with varied volume capacities.

Turntable Wrappers :

A prevalent type of stretch wrapping machinery, they place a pallet on a rotating turntable, with the wrap-distributing system layering the stretch wrap onto the load, generally starting from the bottom up to the top and reversing.

Shrink Tunnel :

When appropriately set, it acts as a powerful packaging mechanism, transporting a product within a shrink wrap through a hot tunnel, wherein the film evenly retracts around the item inside. The machinery’s airflow aids in preventing overheating. For heat-sensitive products, specialized heat-sensing tapes can gauge the product's compatibility with the tunnel. If deemed unsuitable, additional packaging solutions can be recommended.

Skin Pack Machines :

Diverse from blister packaging machinery, skin pack machinery entails a backing substrate or blister board platform onto which products are placed. It envelops the items with a heated, soft plastic layer, commonly utilizing vacuum sealing techniques for a precise fit. The substrate integrates with the sealed layer applied on the cardboard.

In summary, packaging machinery is vital for protecting and maintaining products, minimizing costs, and ensuring proper hygiene standards. The integration of machinery can handle specialized packaging requirements, elevate labor efficiency, and enhance working conditions.

We recognize that selecting the appropriate solutions can feel daunting, which is why we're here to assist you in discovering the machinery your company requires! Reach out to us for a prompt, complimentary quotation.

Packaging Equipments Types

Various examples of packaging equipment include: Collaborative Robots, Lasers for Packaging, Laser Cut, Laser Engraving and Marking, Marking Process, and Package Labels.

Collaborative Robots :

These are either double or single robotic arms that can be instructed to imitate motions or actions. These robots continuously improve their learned tasks over time, performing them efficiently and effectively. Safety measures such as sensors are installed to detect the presence of humans nearby, resulting in the robot slowing or halting operations. In the packaging sector, collaborative robots bolster productivity, aiding in timely placement of products on retail shelves.

Lasers :

Specifically, CO2 lasers prove highly effective in processing packaging materials like paper, cardboard, wood, plastics, and their derivatives. Laser cutting involves the use of a beam to vaporize material along a designated path for clean-cut edges, facilitating cutting windows in packages, easy-to-open tabs, perforations, filtering systems, and components for assembly.

Laser Engraving and Marking :

Both processes utilize lasers to imprint marks onto materials. Laser marking affects only the surface, while laser engraving creates a deeper change to the material, producing more noticeable results. Laser technology allows manufacturers to engrave intricate logos, production batches, expiry dates, and other relevant information onto the packaging.

Marking Process :

This process, similar to labeling, requires identification codes, descriptions, instructions, specifications, weights, and other markings on the external packaging of dangerous materials or hazardous goods.

Package Label :

Labels can be made from materials such as plastic film, paper, metal, cloth, or more, attached to a product or container, conveying information about the item, including barcodes, pricing, UPC identification, usage guidelines, advertising, addresses, recipes, etc. Labels can also deter pilferage or tampering. Depending on the production scale, an automatic labeling machine may be necessary.

Pallets for Packages :

A pallet serves as a flat structure that supports packages securely and is suitable for being lifted by various equipment like forklifts, pallet jacks, front loaders, cranes, or jacking devices. It's the foundational unit load structure, facilitating efficient storage and handling. Items are sometimes positioned on pallets before shipping, protected with stretch wrap, strapping, or shrink wraps.
For operations managing numerous pallets, acquiring an automatic palletizer can be advantageous.
Pallets are essential for providing stable and efficient transport of packages, crafted from materials including wood, paper, plastic, metal, and recycled materials.

Purchasing Packaging Equipment : Applications, Benefits and Drawbacks

When considering the acquisition of packaging equipment, the type of product to be packaged should be factored in, along with considerations regarding shape, weight, dimensions, labeling needs, film printing options, packaging methods, product journey, handling condition, and security requirements.

One option involves direct purchases from manufacturers who can provide detailed insights about their machinery. But, evaluating that manufacturers might exhibit bias could lead to fewer options. In contrast, collaborating with distributors and packaging integrators such as Enoline offers a broader selection of machinery with advantages in cost, customer support, and repair quality.

Additionally, being mindful of environmental conditions is vital when selecting packaging machinery. Machinery operating on pneumatic systems could be considered outdated and may pose environmental concerns; meanwhile, lean technology-based machinery minimizes material use and is more sustainable.

When relocating your production line, consider your machinery's type and electrical requirements for efficient installation. Companies need to determine whether to purchase or lease machinery, assessing timelines, budget, and technological needs.

While selecting a packaging machine and material supplier, it's important to examine their location, technician expertise, customer service, pricing, and parts availability. Opting for inexpensive materials that lack clarity could negate savings from poor service, whereas investing in high-quality options might present essential clarity and appeal. We maintain over 400k+ spare parts in reserve in North America, available for next-day shipping, with our repair team ready to operate globally. Rely on our 30+ years of experience in the packaging domain.

All the aforementioned factors must be considered to make an educated decision when purchasing packaging equipment and materials, aiding in ensuring effective and cost-efficient packaging operations while being aware of environmental and consumer demands.

Applications of Packaging Equipment :

An Extensive Overview The applications of packaging equipment encompass a wide array, including food packaging for various items such as ready-to-eat foods, milk & liquids, spices, coffee, tea, baked goods, and candy/confections.

In the pharmaceutical sector, packaging machinery is utilized for tablets, capsules, oral liquids, granulation, gels, injectables, and powder-based medications.

Other sectors reliant on packaging equipment include agrochemicals, adhesives, pet food, hardware, cement & wall fillers, pigments & dyes, etc.

Benefits of Packaging Equipment :

By investing in packaging machinery, companies reap numerous benefits, such as increased production rates, reduced total ownership costs, enhanced speed, and greater reliability. Manufacturers that produce various quality products can profit from an effective packaging line; with the right machinery, the necessity for manual labor diminishes, thereby reducing overall wage costs.

Moreover, packaging machines allow for higher hourly product output than manual labor, rendering them particularly advantageous for swift delivery businesses. Reliability is another essential attribute of packaging machinery, as they don’t require breaks, vacations, or time off like human workers. Scheduled preventative maintenance can avert potential interruptions due to mechanical malfunctions.

Drawbacks of Packaging machinery and Equipment :

Despite the benefits of packaging equipment, some drawbacks warrant consideration, including the costs and environmental impact. Packaging expenses can inflate overall production costs and retail pricing, particularly in industries like cosmetics, where packaging may represent up to 40% of the final price. Furthermore, the generation of packaging materials can stir up waste concerns, with packaging waste accounting for about one-third of municipal waste in the USA, much of which languishes in landfills. The manufacturing of packaging also consumes resources and energy, contributing to air and water pollution.

Our commitment to transparency and care drives us towards reducing our machinery's environmental impact. We strive to cultivate new sustainable packaging solutions devoid of plastic while providing the most energy-efficient machines available on the market. Choosing Enoline assures durability, productivity, and sustainability in packaging operations.

Conclusion

Packaging equipment and machinery are crucial across industries, significantly influencing product production costs and ultimately impacting sales. Efficiently implemented packaging machinery can decrease production expenses, leading to increased sales and enhanced profitability.

However, reviewing all facets of packaging equipment is vital prior to selection, given the challenges in identifying the most suitable option. Our team is readily available to guide you, offering the finest solutions tailored to your company's specifications. Reach out for a quick free quotation.

We are ready to assist in identifying the perfect packing solution to meet your needs.

Get a fast and free quotation now!