Carton Packing Machine The Guide | Aopack

Welcome to this article, which is an in-depth guide to carton packing machines, If you’re looking for any information about carton packing machines, you will find it right here. So keep reading to learn more.

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1. What is a carton packing machine?

A carton packing machine is a machine for mechanized measures to pack cartons. A carton packing machine, also known as a carton packaging machine, is the use of a machine to automatically wrap cardboard containing glass bottles, PET bottles, cans, large bottles, etc, suitable for beer, beverages, condiments, and food. And other machines all use professional display control. The carton packing machine is greatly convenient to operate and is indispensable equipment for automated large-scale production, which can greatly improve product packaging efficiency.

2. What is the mechanism of a carton-packing machine?

There is some mechanism of carton packing below:

• Container inlet: On the inlet conveyor belt platform, the garden-column type container is divided into multiple lines by the divider plate and the pneumatic vibration rail, while the single-lane entry and special shape of the container are divided into multiple lines by the separation gate.
• Container divider: The container divider is driven by two motor drives to gently and evenly separate the containers. To handle containers that are not stable enough, such as five-jaw PET bottles, transition channels can be used between conveyor chains. After the containers are grouped, they are pushed out by the pusher.
• Cardboard inlet: The cardboard is neatly stacked on a roller conveyor belt and then automatically guided into the lifting cardboard storage located below the container inlet. The vacuum jaw extracts the top piece of cardboard from the lifting memory and places it horizontally on the cardboard inlet.
• Package forming device: The cardboard is transported under the container group and the ends are mechanically folded. The side cover is folded in with a rotating copper, coated with hot melt by the nozzle, and glued to the bottom cover.
• The circulating sealing chain presses against the bottom cover and carries the package through the wrapping machine.
• The top cover is then folded off and glued to the sealing edge.
• Finally, the sealing chain closes the top cover from above. Since the package runs longitudinally and the bottom is already firmly glued, the top cover can be glued very accurately.

3. What are the components of a carton packing machine?

There  are some components below:

1) Fuselage

The fuselage is the rigid skeleton of the packaging machine, which mainly plays the role of supporting and positioning each component. All mechanisms or devices are installed on top of it. The fuselage must be stable and the center of gravity as low as possible to facilitate smooth mechanical operation. The material, structure, shape, decoration, etc. of the fuselage are designed according to the use and characteristics of the packaging machinery.

2) Control system

The function of the control system is to control the relevant parts of the packaging machine and coordinate their process functions. Complete the packaging on time and in order. The devices of the control system mainly include photoelectric control, electronic control, electro-mechanical control, pneumatic control, jet control, etc. The most common system of these is electro-mechanical control.

3) Power part

The power part is the power source of packaging machinery, which can be a motor drive, hydraulic drive, air pressure drive, etc., and is mostly used to drive by an electric dynamo.

4) Transmission mechanism

The transmission mechanism varies from different models and transmits power and movement to various actuators, control elements, auxiliary mechanisms, etc. Its main transmission components are gears, ratchets, cams, sprockets, belts, worm gears, screw nuts, etc.

7) Actuator

The actuator is the core part of the packaging process operation and auxiliary operation and often uses movable mechanical components or manipulators to realize packaging operations. The packaging process operation mainly includes molding, filling, wrapping, sealing, labeling, etc.; Packaging assistance operations include the supply and transfer of packaging materials, packaging containers and products, and the output of finished products.

4. What are the applications of a carton packing machine?

In the early stage of industrialization, the carton has always been packed by manual means, and with the development of large-scale mechanization, the corresponding more subdivided machine came into being, carton packaging machine is also formed in this process, replacing manual labor, the paper packaging machine is widely used in beer, chemical, food, medicine, and other industries, supporting in the filling line, etc., secondary carton packaging for all kinds of bottles and cans, greatly improving production efficiency.

5. What are the advantages of a carton packing machine?

Compared with other types of packing machines, the carton packing machine we provide has the advantages below:

• The modular construction of the machine provides a high degree of flexibility;
• The linear arrangement of the machine makes the packaging of cartons particularly accurate;
• Use the internationally renowned servo control system;
• The control cabinet is pre-wired to make the start fast;
• Short format change time;
• It does not need to be maintained very frequently, and it is very durable;

Other information that you might need to know:

In order to create the greatest benefit for yourself within the specified time, it is necessary to ensure that your packaging production line runs well and there will be no errors in the production process, so as to avoid the impact of errors and failures as much as possible, and only then will the company obtain the greatest benefits.

The level of automation is constantly increasing in the manufacturing industry, and the range of applications is expanding. Automation in the packaging machinery industry is changing the way the packaging process works and the processing of packaging containers and materials. The packaging system that realizes automatic control can greatly improve production efficiency and product quality, significantly eliminate errors caused by packaging processes and printing and labeling, effectively reduce the labor intensity of employees, and reduce the consumption of energy and resources. Revolutionary automation is changing the manufacturing methods of the packaging machinery industry and the way its products are transmitted.

The design and installation of automatic control packaging systems have shown a very obvious role in improving product quality and production efficiency in the packaging machinery industry, or eliminating processing errors and reducing labor intensity. Especially for the food, beverage, pharmaceutical, electronics, and other industries, it is crucial. Technologies in robotics and systems engineering are being further deepened and more widely used.

6. What are the characteristics of a carton packing machine?

There are some characteristics below:

1) Packaging form

automatic transmission, unpacking, boxing, batch number printing, sealing, waste removal, and other characteristics, compact and reasonable structure.

2) Easy to operate

servo/stepper motor, touch screen, PLC programmable control system, man-machine interface display operation is clearer and simpler, high degree of automation, more humanized;

3) Wear protection

the frame and plate have sufficient strength and rigidity, the frame is equipped with the main drive motor and clutch brake of the machine, the machine plate is equipped with various transmission systems, and the torque overload protector can realize the main drive motor and transmission parts in the case of overload to protect the machine parts from damage.

4) The height is configurable

The machine can adjust to different heights to accommodate different sizes of packages so there is no need to change machine molds. It means that one machine can be used for many purposes that show incredible flexibility and versatility of the machine. Generally, it is suitable for all types of corrugated cardboard or lithographic laminated boxes, allowing the operation of a wide range of box types.

5) High safety

if there is no product – the box will not fall, and the machine will automatically stop and sound an alarm.

• The automatic photoelectric detection and tracking system is adopted to save packaging materials, and the box body will not fall due to empty materials
• The vacuum suction cup used by this machine is a ZL112 vacuum generator (SMC), automatic vacuum box taking, wide angle unpacking, to ensure the unpacking accuracy
•  It can be produced with an aluminum-plastic packaging machine, pillow packaging machine, 3D packaging machine, filling line, filling machine, labeling machine, ink-jet printer, online weighing machine, other production lines, and other equipment.
• According to customer needs, design an automatic feeding machine, and box entry system.
• According to customer needs, you can choose hot melt adhesive machine sealing, such as hot melt adhesive spraying machine, or mechanical brushing. 

7. How to operate a carton packing machine?

Here we provide you with four major operation steps of packaging machines and their precautions:

1) Firstly, place the packaging machine material in the right position.

We need to prepare the materials of the packaging machine, such as your products, your packaging containers, the materials of the products, etc., and put them in the corresponding positions for the normal use of the packaging machine.

Notes:

It should be noted here that before using the packaging machine, it is necessary to ensure the cleanliness and hygiene of the packaging machine, especially the packaging machine with filling technology, which is easy to hide dirt, thus causing secondary pollution of the product. In addition, the packaging container should fit the specifications and dimensions of the packaging machine.

2) Secondly, turn on the power switch of the packing machine.

After we have prepared the materials and containers used in the packaging machine, then turn on the power switch of the packaging machine, and the packaging machine is officially started.

Notes:

It should be noted here that before opening the power switch of the packaging machine, it is necessary to check its power line, if the power line has exposed places, it is necessary to replace the power cord in time, otherwise, it is easy to cause the risk of leakage, and at the same time, it is also very easy to damage the packaging machine equipment.

3) Thirdly, packaging machine parameter setting is another important step.

After the power of the packaging machine is turned on, the touch screen of the packing machine will also start, we have to click to enter the parameter setting of the packing machine, according to the instruction manual of the packaging machine to set the temperature, sealing time, sealing speed, filling capacity value and other parameters to ensure the normal use of the packaging machine.

Notes:

It should be noted here that the parameters of the packing machine must be set according to the instructions of the packaging machine, for example, the sealing temperature of the packaging machine is 200 degrees, if the temperature is set below 200 degrees or higher than 200 degrees, there will be bubbles in the seal or the phenomenon of the improper sealing film.

4) Finally, the packing machine starts to operate.

When everything is ready, the packaging machine can be officially started, directly press “start” on the main menu, and the packaging machine can run normally!

Notes:

During the start of the packaging machine, we must observe the temperature of the machine at any time, if the temperature is overheated, we should stop the operation, and wait for the packaging machine to cool down for half an hour before the operation, so as not to cause the packaging machine equipment failure due to excessive temperature. In addition, if the packaging machine has abnormal noise during operation, the packaging machine should be turned off immediately and started after inspection and maintenance.

8. How to choose a carton packing machine?

First of all, you need to determine which products you will pack in the packaging machine you will buy. Packaging machinery manufacturers generally have a variety of products, but some clients in the purchase of packaging equipment, hope to be able to package their own all types of products through a device. In fact, this is a very wrong idea, because generally speaking, the special machine than the compatible machine packaging effect is better. The variety that can be packaged by packaging equipment should not exceed 5 varieties, and the products with too large size differences should be packaged separately.

As far as possible, choose a machine with simple operation and maintenance, complete accessories, and automatic continuous feeding, which can improve packaging efficiency and reduce labor costs, which is suitable for the long-term development of enterprises.

Choose a long-established packaging machine enterprise as much as possible, and the quality is guaranteed. Choosing a machine produced by a mature technology and stable quality enterprise can basically achieve the effect of a faster and more stable machine, low energy consumption, low manual work, and low scrap rate. In the process of use, if you buy a low-quality machine, the packaging film that accumulates and wastes in the future daily production is not a small amount, especially now that the packaging materials are rising.

In terms of after-sales service, the “circle” should have a good reputation. After-sales service is timely and on call, especially important for food processing enterprises for which the freshness of the products is of great importance.

If there is a field investigation, we should pay attention to the big aspects, but also pay attention to the small details, often details decide the quality of the whole machine. Bring samples for testing whenever possible

9. What’s the normal price of the carton packing machine?

The price of a common carton packing machine usually is hundreds of dollars. But there are very expensive carton-packing machines available. Their machines may have some advanced features or the production procedure is very complex.

10. What are the factors that determine the price of a carton packing machine?

There are some factors below:

1) Brand factors

Just like different brands of notebooks, in the case of configuration, appearance, performance, etc., the price of notebooks is generally much higher than that of other brands of notebooks. Just as it is said to believe in the power of the brand, everyone feels that buying branded things makes people more assured.

2) Machine Quality

The quality of the product itself is the basic factor that determines the price. Including the value of various accessories, whether the life and use method of accessories are perfect, the technical content contained in the product, and other information, the quality determines the price of the sealing machine.

3) Market factors

The automatic sealing machine on the market is more popular and has strong demand, which will affect the price of the sealing machine to a certain extent, and the impact of this factor will be reduced due to the sufficient supply in the market. Similarly, in the annual sales season, the price of this machine will be higher, and this market-oriented price fluctuation will not have a substantial impact on the price. However, enterprises can also choose a reasonable time when purchasing machines to avoid these unnecessary passivities.

4) Marketing strategy

All the goods on the market have their own marketing strategies, some of which are not noticed by everyone, but they are reflected in the price.

5) After-sales service system

With the continuous progress of society, people’s sense of service has been slowly cultivated. Now no matter what product you buy, if there is no good after-sales service system, then your product has already lost half. Therefore, when consumers choose a sealing machine, they would rather spend more money and buy a sealing machine from those companies with good after-sales service. Because if the machine encounters problems in the future, then it is also a good guarantee to find after-sales solutions.

11. What are the common problems that may arise on a carton packing machine?

There is sometimes occurred that the electromagnet of the machine does not absorb. The cause of this failure is mostly the internal fault of the host, the solenoid coil being blown out, the line interruption, and other reasons.

The solution is: first check whether the host is internal or external problems;

Secondly, check the electromagnet fuse, check whether the electromagnet has signs of power, eliminate mechanical jamming, and detect the internal power supply when everything is normal; Often encountered in the weighing packaging machine is the cause of this failure: sensor damage, bridge voltage failure, line connection or interruption is wrong, the elimination method is: detect the load signal of the sensor and the connection or host, close to detect the bridge and amplification circuit or computer output display circuit, sometimes there will be poor system stability resulting in unstable bag volume to solve this problem can test whether the line is in good condition.

However, the weary of parts in use and poor lubrication will cause damage to parts and may expand the occurrence of faults and accidents, so it is very important to quickly find and eliminate faults. Don’t turn to the manufacturing plant for a glitch and win valuable time and money.

Here are a few places and repair methods that are prone to failure:

• Fault: Cut the steel strip
• Causes:

1) Cutter wear or failure

• Maintenance method: check whether the cutter or cutter holder is worn or faulty, if the wear is serious, it should be replaced

2) Air pressure decreases

• Maintenance method: check whether the working pressure is normal;

The cutting steel belt force comes from the blockade cylinder see fault phenomenon;

Check the blocking operation:

• Fault: The locking clamp is not subjected to enough pulling force
• Cause: Clamp block connection holes or connection pins are worn
• Repair method: Check these parts when the groove depth is shallow and replace them if necessary.

12. How to maintain a carton packing machine?

A machine only operates better if you take good care of it. Asides from the daily operations, you also need to pay attention to taking good care of it. The maintenance methods we would like to provide you with include:

Types of Pallet Wrappers

First of all, you will need to decide if you want a semi-automatic or automatic stretch wrapping machine*. Space, capital, speed, capability, and needs are all important considerations for this decision!  

A semi-automatic stretch wrapper is manually placed on a turntable and a piece of wrap is placed at the bottom of the pallet. from there, the machine will wrap the load according to your selections on the machine for load containment. The finished pallet is manually removed from the turntable and the next pallet is moved into place. 

An automatic stretch wrapper takes a pallet and automatically puts it in the wrap zone where it is wrapped based upon the settings of the control system. When completed, the pallet moves down a conveyor to the end of your packaging line. As your fully wrapped pallet completes its journey, the next pallet is automatically being conveyed into the wrap zone.

*There is also another option called "simple automation" which is available from select vendors. This form of simplified automation allows for what is called "cut and clamp capabilities" which means that your machine operators are not required to get off their fork trucks to operate the control panel. This form of automation allows the equipment operator to drop the pallet onto the wrapper while the machine pushes it onto a roller conveyor.

Pallet Wrapper Dynamics

In addition to the types of pallet wrapping machines mentioned above, there are different types of wrappers with different functionality. When trying to figure out which pallet wrapper would best suit your needs, you will want to research the following kinds of equipment: turntable wrapper, straddle wrapper, orbital wrapper, or ring straddle wrapper.

Each of these machines wraps pallets in a completely different way and each offers different variables to their load containment. Each type of machine is also meant for different applications. Reviewing the specs for each kind of machine and how the machinery is operated via video or live demonstration is highly recommended.

1. Turntable Wrapper

With this particular machine, the pallet is put on a turntable that spins while a wrap delivery system allocates the stretch wrap to the load being wrapped. The wrap delivery system generally begins at the bottom of the load and wraps up to the top and back to the bottom. Turntable wrappers are one of the most popular kinds of stretch wrapping machines and can be set up to work well with various types of applications.

2. Straddle Wrapper

With straddle stretch wrappers the load stays immobile while a wrap delivery system spins around the load being packaged. This kind of wrapper can wrap unstable, lightweight, and heavier loads and is capable of wrapping from low to high volumes.

3. Orbital Wrapper

An orbital wrapper (also known as a "ringer") wraps a pallet by going over and under the load being packaged as the load travels on a conveyor into the machine. Orbital wrappers are primarily used for packaging flattened or oddly shaped items such as pipes, rolled carpets, windows, etc.

4. Ring Straddle Wrapper

Ring straddle wrappers are fast wrappers that are generally able to wrap 200 loads per hour. These machines are often found in the toiletry and beverage industries. They are extremely specialized devices and only make up a small portion of the stretch wrapping machines currently in use.

Straddle pallet wrappers allow for the load to stay still while the wrap delivery system spins around the pallet. It then pistons up and down while the film is evenly distributed around the pallet.

How Much Does A Shrink Tunnel Cost?

There are various elements of a shrink tunnel that will affect the total purchase price of the machine. From the type and gauge of shrink film that you choose to run to the optional items you add to the machine, there are various things that can increase or decrease your total purchase price.

Below is an example that will give you a solid understanding of the total cost of a tunnel. Keep in mind, higher speeds and different options bring on different models and larger investments. 

Kallfass COMPACT 650 S

Compact and energy-saving shrink tunnel with patented ring nozzle heating system and especially effective regulation of the air volume. Equipped with a plastic mesh conveyor, for low maintenance and superior shrink results. This tunnel is ideally suitable for the shrinkage of small to medium size products with medium-capacity requirements.

Included Features:

• Variable transport speed and blower speed
• Maintenance-free plastic mesh conveyor
• Automatic cool down with automatic power shut off
• Energy-saving two (2) stage heating system
• A wear-free heating system without contactors
• Tornado style airflow system to prevent dog ears and burnouts

Base Machine Cost (Includes NO additional options): $21,900

Technical Specifications:

• Maximum Speeds: 100 PPM
• Clearance in Height: 8” max.
• Maximum Product Dimensions: approx. 22” W x 7” H x random length
• Conveyor Speed: 115 feet per minute
• Voltage: 208V – 480V, 3 Phase with Ground (specify with order)

Additional Options:

• Clearance in height 12” or 16” \ $1,500
• Special color (structure lacquer, monochromatic) $500
• Tunnel casters $500
• Plugs for power and signal connection to machine $ 500
• Lockable cover for controls $ 300
• Tunnel chamber with window and light $ 2,400
  
  

What Are The Most Reliable Shrink Tunnels

While there are multiple OEMs producing shrink tunnels, we have found that the most reliable shrink tunnels are produced by Kallfass and Extreme. Both feature extremely high-quality parts and materials and are considered leaders of the pack when it comes to this particular type of packaging machinery.

Our team finds that the Kallfass Universa 500 and Servos machines rate the best overall.

Common Shrink Tunnel Issues & Possible Fixes

As with any type of machinery, shrink tunnels and the materials run through them have common issues that can arise due to certain variables such as temperature. Here are a few of the most common problems that arise when the temperature is not optimized correctly.

● Flat Films Not Coming Off The Roll

○ When layers of flat film stick together, it’s called “blocking.” Usually, the film has been in excessive storage temperatures, which causes it to fuse together.

● Jagged Seals Or Incomplete Cut-Offs

○ Seals that look torn, incomplete, or jagged suggest that seal temperatures are too low. Try turning the heat up at 25°F increments until the film has a clean seal and sharp cut-off.

● Shrink Bags Take Too Long To Seal

○ Dwell time (how long it takes for the film to seal when the seal jaws are closed) varies. If dwell times are rising, it suggests that the temperature is too low, and vice versa.

● Strands Known As “Angel Hair” Start Showing Up Near The Seal

○ Strands that look like hair can appear between the sealed shrink film and the sealing mechanism. These are caused by the sealing wire or seal bar not being hot enough.

● Smoking Film Or Build Up

Further reading:
Can a Portable Power Station Run an Air Conditioner? - EcoFlow
Everything You Need To Know To Find The Best Automotive Parts Shredders

Are you interested in learning more about Pallet Wrapping Machine? Contact us today to secure an expert consultation!

○ Smoking and polymer build-up on a pad demonstrate excessive heat. Worn pads can also create polymer buildup and smoking. It’s best to reduce excessive sealing head pressure and align them.

Of course, for every problem, there is a solution and for these issues above, honing in the correct temperature will largely fix all of them.

What temperature should you store your shrink film at?

When storing your shrink film prior to use, make sure that you have a general idea of the best practices for the extremes of both summer and winter storage. During these times of the year, temperature restrictions are of utmost importance for these materials. If shrink film gets too hot, it can melt and stick to itself. If shrink film gets too cold, it can become brittle and crack.

Overall, shrink film is best stored in temperatures between 30 and 77 degrees Fahrenheit. Naturally, summer and winter are the seasons that require you to be most attentive to your storage environment.

What temperature should you run shrink film at in your heat tunnel?

The inside of your heat tunnel is an important dynamic to have locked in prior to packaging your product. The correct temperature for your product depends on which kind of substrate is being utilized. Furthermore, the appropriate heat for your product also depends on the gauge of your shrink film. More often than not, the most typical type of material run through a heat tunnel is 45 - 75 gauge PVC or polyolefin shrink film.

Let's run over a hypothetical situation that will allow you to better understand heat restrictions for your shrink films as they are passing through your heat tunnel. Say you are currently running a 75 gauge PVC shrink film:

An appropriate setting for PVC would be between 215 – 235 degrees Fahrenheit. Now, if you are going to use a polyolefin film with a gauge of 75, then an appropriate temperature for your heat tunnel would be about 255 – 275 degrees Fahrenheit. Keep in mind, these are just ballpark figures, and depending on the dynamics of your equipment, materials, and product, your actual settings may vary.

While it is technically possible to run a packaging department almost exclusively on human physical labor, most of the time it is neither a good or correct solution.

It is true that packaging machinery comes with a significant up-front financial cost, but the dividends that a quality packaging line with robust machinery can payout are worth their weight in gold. Below, we will take a look at the many benefits of using packaging machinery on your packaging line.

Production

When it comes to producing a large number of quality products, a robust packaging line can make or break a company. This is especially true if you are producing a high volume of products in a short amount of time.

Sure, you can lean heavily on manual labor, packing tables, cardboard boxes, tape, and hand film. That being said, is it really a sound investment if your volume is more than your team can manage consistently?

Investing tens, hundreds, or in some cases millions, of dollars into packaging machinery can be daunting, but the money that this machinery can save for your company over the long term can make the investment worth it.

Furthermore, with financing and leasing options, getting your hands on the packaging equipment you need to take your production and your company to the next level is easier than it has ever been in the history of packaging.

Total Cost of Ownership

The total cost of ownership is one of the most important dynamics to consider when you are weighing your options in regards to your packaging department. With the right packaging machinery, you will require a smaller labor force, therefore paying out significantly fewer wages.

Indeed, packaging machinery can come with a relatively large price tag, but when you take the total cost of ownership of a semi or fully automated packaging line and compare it to a warehouse full of manual laborers, the numbers begin to lean in the direction of machinery as the most viable option for success.

Taking the time to compare what you are paying for your labor force (not only in money and time but also in regards to hiring, firing, sick time, and vacation) to a primarily mechanized line may surprise you. Chances are, you may very well find that in reality, a machinery-driven packaging line with a few well-trained and dedicated operators is the better choice both financially and logistics-wise.

In other cases, you may find that right now is not the time to seek out the investment, but it's worth reviewing on a regular basis to make sure you are considering your overall costs and your future business goals and expectations.

Speed

Packaging machinery allows you to package more products per hour than physical labor. When the speed of getting your product to market is an important dynamic for your business, ensuring that you are running packaging machinery vs. physical labor is extremely important.

Human beings simply cannot package products as quickly or efficiently as an automated or semi-automated mechanical packaging line.

Reliability

Packaging machinery does not take sick, personal, or vacation time. While downtime may occur due to mechanical failure or a broken part, these issues are easily remedied and are few and far between when you plan your downtime. When coupled with a regular preventative maintenance program, a mechanical packaging line can save you thousands of wasted dollars and hours per year.

An Eye Towards The Future

As packaging machinery technology advances, we are going to see major leaps in speed, quality, and most importantly, automation. Packaging machinery is going to the robots and they are going to become the norm on the best packaging lines throughout the world for various reasons. The better prepared you are for this transition, the better off your company will be.

Production line automation allows companies to leverage ingenuity and efficiency without sacrificing craftsmanship or quality. With an automated production line, you never have to worry about employees getting sick, you can rest assured that production levels will remain high, and you can feel confident knowing that the end product will be made to a consistently higher standard.

Robotic packaging automation, in particular, mimics human movements to take the human being out of the process without sacrificing the yield of the process. This does not eliminate the need for good staff. Instead, it provides an opportunity to remove the repetitive, unskilled tasks that many humans find boring and unfulfilling yet are critical to meeting production needs.

In other words, robotic packaging automation provides an opportunity to maximize your staff while maintaining or increasing productivity. That’s a win/win situation for you, your employees, and your company.

Tips To Manage Packaging Machinery Costs

Negotiate Your Equipment Costs

When meeting with your sales rep, ask about special offers, rebates, and additional opportunities to reduce the cost of your purchase. Packaging machinery is a big investment and there may be various ways in which you can reduce the price of your purchase.

Keep It Simple

When buying a packaging machine you are likely going to get an offer from various sales reps. Unfortunately, many sales professionals will try to sell you a Cadillac when all you really need is a Toyota. When getting quotes from your chosen vendors be sure to ask about getting a base machine with no bells and whistles and only adding the options you actually need to successfully package your products.

It is also important to ask for quotes from several different manufacturers. Sometimes you can get a virtually identical offering from one company that is thousands of dollars less than their competitors despite any major difference between theirs and the other vendors' machinery.

Truth be told, sometimes you are simply paying extra for a brand name. When it comes to packaging equipment, buying a product because it is the most famous brand in the industry does not always translate to the best-packaged goods.  You may actually get a better machine from a lesser-known brand that packages your product perfectly.

Weigh Your Options

There are several dynamics for purchasing packaging machinery and their associated operation that is not a cookie-cutter solution for every business. There are some aspects of buying and running packaging machinery in which there are at least two options. One option may be right for your business and wrong for the next. These include:

1. Buying new, used, or refurbished equipment. Each of these options comes with very different price points and its own major strengths and weaknesses. As for which is right for you, this will largely depend on your budget, products, and the materials you choose to run on your equipment.
   
   
2. Hiring versus contracting technical service. For some companies with large productions and a packaging line that runs 24/7, a dedicated in-house service technician may be a good investment, but it is not the best fit or the right choice for all companies.
   
   
3. Working with a distributor versus buying direct. Each of these options has various pros and cons. Which makes the most sense for your business? That is entirely dependent upon your unique needs. Getting quotes from both a distributor and an OEM will allow you to compare the pros and cons of each and make an educated decision on which vendor is a better fit for your company.
   

Preventative Maintenance

A preventative maintenance plan is an additional cost to consider when buying packaging equipment, but it will save you thousands of dollars. When parts wear out, they can cause breakdowns that may result in extensive downtime and lead to highly costly repairs. If you are on top of regular maintenance, you will reduce the risk of more damage.

Damage may occur to other parts of your machinery when a worn-out part fails, let alone the risk of injury to your workforce. A regular preventative maintenance plan will greatly reduce downtime, keep your machinery running at peak performance and ensure quick repairs and service calls.

Try Different Material Formulations

A different material formulation may reduce your cost on the machinery that runs it. IE: stretch wrappers and shrink machinery. What many companies often overlook is that there could be more than one kind of material that works for a particular product.

Get A Machinery Analysis

Bring in a rep from a couple of different vendors and have them run an analysis of your current packaging line. This will give both of you a large collection of valuable information about your particular packaging processes such as your current equipment, materials, and procedures. This information will allow you and your rep to find ways to improve upon your current processes before upgrading to new machinery.

It is important to identify some specifics about your product to be packaged before buying a piece of packaging machinery. For example, the materials that you will be running on your line are an important consideration when planning to buy new equipment.

If you are going to be buying shrink film machinery, you will want to look at all the different kinds of shrink film as well as the various gauges of films that are available. Choosing the wrong type, gauge, and size of the film can cost your business thousands of dollars over time.

Some of the packaging considerations you’ll need to be aware of include:

• What type of product you are packaging
• The product’s weight, shape, and dimensions
• Your objectives for color and labeling
• Whether the film can be printed to meet your needs
• How the product will be packaged into the flexible film (manually or via machine, and what type of machine)
• The product’s journey from creation to shipment to the shelf and beyond
• Whether it will be handled often and/or subject to rough handling
• The types of climates/environments it will experience
• Whether it requires specific film additives to keep it fresh (e.g., oxygen or moisture barrier)
• Requirements for anti-tampering and security of the finished good

Key Consideration: Working With A Distributor VS. Buying Direct

When you are trying to figure out where you should buy your packaging machinery from, choosing to go direct to the manufacturer is a common choice. After all, who knows their machinery better than the people who are building said machines? You can be sure that the manufacturer knows their equipment inside and out. As such, they should be able to answer your most discerning questions.

That being said, the manufacturer will obviously be biased when answering questions like "which is the best brand of packaging machinery to buy" or "which manufacturer offers the best service"?

Now, just as there are various ups and downs when buying from an OEM, so it is with a distributor. From the cost of goods to customer service and quality in repair work, distributors have their strengths and weaknesses.

Depending on various factors including your geographical location, budget restraints, and other dynamics such as your production line's current infrastructure, a distributor may or may not be the best choice for your company.

There is an absolute myriad of considerations when choosing packaging equipment and materials are one of the most important items to consider. In addition to packaging machinery and materials, the environment and atmosphere also are important dynamics to ponder. Working with a distributor will allow you to review a plethora of options and they will be able to help you acquire the right information, advice, and products for your needs.

Key Consideration: Extreme Temperatures

Extreme heat or cold must be offset by heating or cooling systems where extreme temperatures are the norm. Whether this means you live in a place where it is always one extreme or the next, or if you live in an area that can see both extremes throughout the year, ensuring that you have the proper heating and cooling systems in place is something to take seriously.

Key Consideration: Environmental Concerns

When it comes to the environment and packaging machinery, one thing is for sure. You do not want to run pneumatic machinery. Pneumatic technology is not only extremely outdated, but it is also bad for the environment as it uses an excessive amount of electricity.

Some machines have completely eliminated pneumatic components all together which results in huge cost savings as compressed air is one of the costliest utilities in a plant.

Benefits of using non-pneumatic machinery include:

• Top-level performance with light gauge films, as well as, PE films.
• No Product/No Bag. So, you’re not disposing of the material.
• 10-15% film savings on average.
• Energy regeneration with every cycle.

Since air cylinders wear, eliminating pneumatics will reduce purchasing replacements and the disposal of them as well. Some non-pneumatic machines also offer what is called “servo technology” which does not require you to add additional floor space and multiple conveyors to get the correct spacing between products.

Other machines also offer what is known as “lean technology” which eliminates film breaks. This means you don’t have to re-wrap loads and throw extra material away. Typically, machines with lean technology use less material with a special metered film delivery system.

In addition to negating or removing pneumatic technology from your packaging line, being sure to run environmentally friendly materials is also an important consideration.

While much of the metals that make up packaging machinery can be recycled, certain materials can not or simply are not recycled.

When choosing materials for your packaging it is important to consider using flexible packaging materials like shrink film and stretch film in place of high carbon footprint items such as glass, metal, and cardboard.

While also being considerably cheaper than these other materials, shrink film and stretch film are in fact completely recyclable. And with a significantly lower carbon footprint than the aforementioned alternatives, flexible packaging materials are in fact a far better choice for the environment.

Key Consideration: Moving Your Production Line

Depending on the types of machinery you are running and how said equipment is laid out, it would be wise to create a plan for moving the right equipment at the right time. Depending on the size, electrical requirements, physical location on your line, and weight of your machinery, some planning ahead of time is an important dynamic of this process.

Reaching out to your packaging machinery and materials representative to help you formulate a plan based on the dynamics above will allow you to take a preemptive strike against unnecessary or repetitive actions during the transportation and installation of your machinery in its new location.

Depending on the flow of your packaging line, certain machinery should be installed first to ensure an efficient and timely installation. As for which machine you should move first, well, this is case sensitive for every business and should be decided by you and your technical service contact.

Key Consideration: Should You Buy Or Lease Your Machinery?

Buying new machinery is a big investment for many companies and oftentimes buyers are unsure or uneducated about the process. One very important consideration to think of right off the bat is, should you buy or lease the machinery you are planning to acquire?

The truth is neither option is one size fits all. Each has its own pros and cons and a different set of applications and line dynamics that would suggest one superior to the other. Ultimately your unique needs, layout, and budget will determine which option is best for your business.

There are however some considerations to ponder that will help you to decide which option is best for your packaging line and the unique applications in which it is involved. So with that in mind, let's review a few key elements of choosing to buy or lease your packaging machinery.

1. Focus on Your Overall Needs and Time frame.

Capital investments should be made strategically and with the future in mind. Some of the things you'll want to consider when vetting leasing new packaging machinery over financing include how much you plan to use the machinery, how many machines you will be looking to acquire, potential investors in your business, and last but not least, your balance sheets.

2. What is Your Budget?

Does it make more sense to buy your machinery outright or do you need to start out with leasing based on your budget? In evaluating/making a purchasing decision on equipment, people sometimes confuse the ability to justify the purchase with the ability to pay for the purchase. The ability to justify the purchase (ROI) is based on a business decision that the payback meets your requirements for investment.

3. What Type of Technology Do You Need?

If you want to have the best machinery on the market, you may have to do a little extra digging to find newer technologies that offer the best lease options for your business. That isn't to say that they won't be available, it just may take some extra legwork and research. Therefore, having a supplier that has experience in equipment leasing within the packaging industry is important.

How To Choose A Packaging Machinery And Materials Supplier:

When it comes to choosing a supplier for your packaging materials and machinery, it is important to do your homework and ask yourself a few questions. You should investigate at least three different suppliers and learn about several important dynamics from each of them.

Location

It is a good idea to choose a packaging machinery supplier who is relatively close to your geographical location or can easily travel to you. This will have an impact on your business when there is a need for repairs or emergency service for your equipment. Pick a supplier who is in another country and you may find yourself dead in the water for days on end. Choosing a supplier with technicians who are local is always a smart idea. When it comes to your materials, you don't have to be as worried about the physical location as most supplies can be shipped timely.

Technicians

It is important to choose a packaging machine supplier with experienced and certified technicians who are professionally trained to work on your packaging equipment. Without the proper certifications, you are taking a chance with your equipment. You could end up paying big when risking service with non-certified techs.

Customer Service

It may be tempting to source the cheapest packaging materials in an attempt to save money, but if you buy from a company with poor customer service, you may end up losing the anticipated savings anyway. Poor service often means lost dollars. Check out reviews of each vendor and if possible, reach out to current customers and ask about their vendor's customer service and if they would recommend buying from them.

Cost

There is an old saying in the packaging industry and that is "shrink film is shrink film". While there are some brands with flashy marketing and sales gimmicks with a premium price, chances are, there are several less costly alternatives that are of equal quality. If you are looking for comparisons, there are generally low-cost films that have lower clarity and higher-cost films that will shine more and have better clarity. Choosing an inexpensive film may cost you in shelf presence.

Snake oil and elevator pitches can blur the line between reality and illusion. At the end of the day, you will want to purchase from an honest supplier who carries multiple offerings at different price points and provides superior customer service.

Parts

Depending on how often your machinery is running, your downtime due to repair needs or emergency service will vary. As time is money, it is important to ask your machine supplier about lead times, parts availability, and preventative maintenance programs.

Ask each potential vendor what their average response times for emergency calls are. In most cases, it should not be more than 24-48 hours.

Which Packaging Materials Should You Use?

Different types of machinery require different types of materials and utilize different amounts of materials based on the make and model of equipment. For example, while you can save money upfront by purchasing a manual L-Bar Sealer, your cost of goods will likely be higher as a more expensive automatic sealer will generally use less material than the manual machine because the machine will generally be optimized to do so.

That being said, the quantity of product that you will be producing must also be taken into consideration. An automatic sealer won't be the right machine for a small business that is only running a couple of thousand items or less each week.

This is due to the fact that each model is designed to work with specific maximum and minimum capabilities and materials. Every machine is different. Your packaging line's unique needs must be taken into consideration when choosing the appropriate machine for your application. This can result in higher production costs if your choice of machinery cannot run thinner gauge shrink film. Using thinner gauges of shrink film can result in significant cost savings.

Conclusion:

Buying packaging machinery is a major investment. The various dynamics of choosing machinery include; safety, budget, physical layout, electrical supply, materials, and a whole host of considerations that can make your head spin.

When moving forward with the buying process it is important to start by reviewing the appropriate KPIs with an emphasis on safety first. Next, you will want to be sure to complete the packaging machinery pre-investment checklist. After filling out the information in this valuable tool and getting your results back, you will want to move on to getting quotes from at least two or three vendors.

Getting an analysis of your packaging department and collecting data on your current machinery, manual labor, materials, physical footprint, electrical requirements, production levels, types of products and the other important dynamics of running a safe and productive packaging line is key.

Once you have been able to fully analyze every aspect of your packaging line, asking for quotes from each of the vendors you are giving an opportunity to quote will provide you with peace of mind that you are going get the best deal and receive the best of what each vendor has to offer.

In addition to requesting information and pricing on the packaging machinery you are looking to purchase, be sure to also acquire information about the cost of service, installation, any training available, supply, and repairs. Ideally, you should consider getting a quote for a long-term preventative maintenance plan as this type of program will ensure that your machinery is always running at peak performance and that downtime will be limited when it does occur.

Once you have chosen a vendor to buy from, meeting with your representative and reviewing the machinery offerings that they have will allow you to open a conversation about pricing. Here you can ask about special offers, rebates, additional options, leasing versus buying, and other related dynamics that will help you to get the best price and best plan implemented for your specific budgetary restraints and packaging line needs.

Finally, it would do you well to schedule quarterly, bi-annual or annual meetings for review with your chosen vendor's sales representative and one of their maintenance technicians.

This will allow you to review data from one meeting to the next and identify places where your machinery and materials could be improved upon to further reduce your cost of production, increase speed to market, create greater efficiency and produce a superior performance on your packaging lines KPIs.

Once you have purchased your new machinery and have worked with your chosen vendor to install the machinery, train your operators, and all else has been said and done, be sure to schedule your first review before your representative leaves your building.

If you heed the information in this guide, we assure you that you will make the best possible choice of packaging machinery for your packaging department. Furthermore, you will be able to ensure the purchase and implementation of the best materials for your products and may rest assured that you have done everything in your power to have the best possible packaging line for your business.

Should we not have produced answers to some of your questions or content that is crucial to your particular needs in regard to buying new machinery, contact us directly. Your voice can help others in your position in the future!

Our dedicated packaging professionals can and will answer any questions that have not been answered by this guide. In addition to what you have read here, we invite you to peruse our blog which is absolutely packed to the brim with useful information, free tools, and quality content that will make for a highly useful adjunct to this guide.

Last but not least, you will find a selection of free tools below that will help you on your journey to finding the best packaging machinery for your packaging line.

From all of us here at Industrial Packaging, we wish you well on your quest and again would implore you to contact us if you need anything else that you could not find in this guide.