Packaging automation - how to gain efficiency without stopping production?

Estimated reading time: approx. 8 minutes

TL;DR

• Packaging automation increases productivity and reduces logistics costs.
• It is crucial to maintain production continuity during implementation.
• Robotisation minimises errors and improves ergonomics.
• Modular solutions allow flexible adaptation to a changing product range.
• The support of an experienced integrator guarantees a rapid return on investment.

Table of contents

• Introduction
• What is packaging automation?
• Benefits of packaging automation
• How to automate the packaging process without stopping production?
• Robotisation of packaging in practice
• The most common problems and how to solve them
• Internal linking - additional information
• Why work with Michale Automation?
• Practical guide: guidance for decision-makers
• Conclusion: profits in the short term
• Summary
• FAQ

Introduction

Automation of the packaging process is becoming one of the key elements in optimising production lines in modern plants. According to various sources, the implementation of advanced packaging systems can reduce logistics costs by up to a dozen per cent, as well as significantly reduce errors during the packaging of goods. In an era of increasing customer expectations in terms of speed and quality of delivery, automation not only helps to increase a company's competitiveness, but also increases employee safety, improves ergonomics and minimises downtime associated with manual packaging.

In this article, we will discuss why automation of the packaging process is so important for manufacturing companies and how to implement it step by step, without having to stop the entire line. Among other things, we will describe the benefits of introducing mechanical and robotic solutions, as well as signalling what to pay attention to in order for such an investment to bring the expected return. You will learn how Michale Automatika, the official distributor of SIASUN robots, can support your company in the process of packaging robotisation and how to use its experience in machine building, production lines and industrial automation.

What is packaging automation?

Packaging automation is the implementation of machines or robotic workstations that carry out the tasks involved in packaging products - from forming and closing the packaging, to labelling, to palletising and preparing for shipping. The aim of such optimisation is to speed up work, increase productivity and maintain high repeatability and quality of packaged goods.

In some industries - such as food, cosmetics or pharmaceutical production - automation of the packaging process is particularly desirable. For example, in short runs where flexibility is important, collaborative robots (cobots) can take over variable packaging tasks. In high-volume plants, on the other hand, packaging machines are designed for continuous 24/7 operation.

Benefits of packaging automation

There are many measurable benefits to implementing automated packaging. Here are the most important of these:

Increased productivity

• Automation enables high volumes to be handled without the risk of bottlenecks arising from the limitations of manual work.
• A single packaging line can process up to several hundred per cent more packages in a day than a human operator working in manual mode.

Fewer errors and returns

• Machines and robots ensure repeatability, reducing the risk of mistakes in order picking or labelling products.
• Precise stacking and sealing of packages minimises damage to goods, resulting in fewer complaints.

Improving work ergonomics

• Operators do not have to carry heavy parcels, bend or perform monotonous manual tasks.
• Reducing physical strain has an impact on reducing accidents and injuries.

Cost optimisation

• Decrease in manual labour costs and errors in the packaging process.
• Careful planning of automation reduces order handling times. With high volumes, this translates into significant savings.

Increased line flexibility

• Packaging robots can be quickly reprogrammed for new products or changing customer requirements.
• Modular machines allow the packaging system to be expanded as the company grows.

How to automate the packaging process without stopping production?

Many companies fear that implementing automation may require downtime and consequently cause delays in order fulfilment. However, with the right preparation and expert support from integrators, it is possible to carry out the installation and configuration of machines step-by-step without stopping the entire line. Specific steps are outlined below:

STAGE 1 - Process audit and needs analysis

The first step is to conduct a thorough analysis of your current packaging system.
- Identification of current problems: Is there a shortage of staff? Are there mistakes in picking products?
- Production variability analysis: Do you pack only one type of goods or a dozen variable SKUs per day?
- Assessing potential gains: How much time and resources can be saved through automation?

Based on this data, an integrator, such as the Michale Automation team, can develop a concept for a robotic station or packaging machines tailored to the needs of your line.

STAGE 2 - Technology selection and requirements formulation

Once you know the bottlenecks of the process, you are faced with the choice of technology.
- Industrial robot or cobot? High-performance industrial robots work well where high speed is important for repetitive tasks. Cobots may be better for processes that require more flexibility.
- Packaging machines: Automated lines can include machines that form and close cartons, apply labels or control weight systems.
- Use of vision-based inspection systems: The use of cameras and sensors can help detect misplaced or damaged packaging.

At this stage, you determine whether you are planning full automation (from picking the product from the belt to palletisation) or only support the operator in a selected step, such as closing and labelling the packaging.

STAGE 3 - Design and integration into the existing line

The next phase is the development of a detailed design taking into account ergonomics, security and compatibility with the existing production environment.
- Interaction with PLCs and the plant control system: the automation integrator configures the interaction of the new machine or robot with your production management system (ERP/MES).
- Off-line testing: With 3D simulations, it is possible to see how the new packaging module will affect the workflow and whether it will deliver the expected throughput.

At this stage, it is also worth tapping into the expertise of companies such as Michale Automation. As an official distributor of SIASUN robots, the company has access to a wide range of industrial robots, so it can help you choose the right solution - from handling small packages to transporting heavy cartons.

STAGE 4 - Assembly and commissioning (without stopping production)

To avoid having to completely shut down the line, the integrator can schedule installation and testing during downtime or weekends.
- Gradual connection of modules: First an additional conveyor or rotary table is installed, and only then is the robot introduced.
- Parallel operations: the line continues to work in the traditional way, with a new module gradually taking over some of the tasks in parallel.
- Short performance tests in production mode: Allow you to catch details for improvement without blocking the overall process.

This ensures that implementation does not cause long delays in order fulfilment and that your company does not risk losing continuity of supply to key customers.

STAGE 5 - Employee training and optimisation

The final important step is to ensure that the team is competent:
- Train staff in the use of machines and robots. It is worth preparing operators for any emergency situations.
- Set targets and performance indicators (KPIs) to measure the effects of automation.
- Regular maintenance and inspections keep the equipment fully operational and minimise the need for service when it is least convenient.

After the start-up period, further optimisation steps are carried out, e.g. speeding up motors, improving control logic or adding visual quality inspection systems to further improve the overall process.

Robotisation of packaging in practice

An excellent example is provided by production facilities where robots have been implemented to palletise large cartons and crates. One industrial robot can handle several types of packaging of different sizes, palletising them according to a set pattern. Thanks to automation:

• Reduced total packaging time by 35%.
• Packaging placement errors were reduced, reducing the risk of damage in transit.
• Operators took on more complex quality control tasks, reducing monotonous and physically taxing tasks.

In smaller plants, packaging often involves products that require precision, such as bottles, cosmetics or electronics. In such situations, collaborative robots (cobots) with a large range of movement can support operators without taking up much space. This makes it possible to maintain production continuity even when the product range changes frequently.

The most common problems and how to solve them

Despite its many advantages, packaging automation comes with some challenges. It is worth knowing these in order to counteract them effectively.

Lack of qualified personnel to operate the robot

Solution: Plan training as early as the design stage of the workstation. At Michale Automation, we offer support in this area, as well as warranty and post-warranty service.
It is worth considering signing a service and maintenance contract so that specialists can respond quickly to any faults and carry out regular maintenance.

Failure to adapt automation to a changing product range

Solution: Choice of more flexible machines (e.g. cobots or modular packaging systems). If necessary, a changeover or replacement of grippers is all that is needed, rather than a complete change of line.
Prototyping: it is worth testing machines in different scenarios before full implementation.

Excessive investment costs and uncertainty of return

Solution: Create a sound business plan based on concrete performance indicators.
Use ready-made tools such as ROI calculator - Welding robotisationto see how quickly the expense of automation can pay off.

Internal linking - additional information

If you want to explore the topic further robotisation of packaging and find out how precision machinery can optimise production even in small plants, visit: Robotisation of packaging.

When planning further implementations in the industrial process area, it is also worth looking at:
Robotisation of repetitive production - if your facility is dominated by repetitive tasks requiring a high degree of precision.

In addition, remember that regular servicing and maintenance of stations will ensure less downtime and allow your packaging line to run at top speed.

And if you're considering calculating the anticipated gains from robotisation, related to more than just packaging, then use our practical ROI calculator - Robotisation of welding. The principles of ROI analysis are also similar for other areas, including the packaging process.

Why work with Michale Automation?

For years, Michale Automatika (often renamed Michale Automatika) has specialised in the construction of machines, production lines and the implementation of robotic workstations in companies of all sizes. As an official distributor of SIASUN robots, we supply and integrate first-class robots, connecting them to the existing infrastructure of companies.

The advantages of working with us:

• Comprehensive turnkey approach: from audit and concept development, through design and testing, to commissioning and service.
• Flexibility of implementation: we can automate the packaging process even under difficult production conditions, scheduling assembly during short overnight or weekend downtimes.
• Experience across a range of industries: We carry out projects in the food industry as well as in the automotive, metallurgy or cosmetics sectors.
• ROI support: we assist in creating sound profitability calculations so that the investment makes good business sense.

Practical guide: guidance for decision-makers

Automating the packaging process brings immediate efficiency gains, but also requires careful preparation and commitment from all departments. Here are some key tips:

1. Set clear objectives and KPIs

Before introducing a packaging robot, think about what specifically you want to achieve:

• Do you want faster packaging, reduced errors or improved ergonomics?
• Establish measurable indicators, such as the number of packages per hour or the percentage of packaging errors.

2. Plan your budget with a reserve

The cost of automation is not only the purchase price of the equipment, but also the implementation and possible outsourcing of certain elements (e.g. integration with an ERP system).
It is worth including a provision for modifications, which often prove necessary after the first tests.

3. opt for flexibility

This is especially true for packaging lines that handle different types of products with varying product mixes:

• Choose modular equipment and robots that can be reprogrammed when changing packaging.

4. Ensure the safety of people and machines

In the case of robotisation, safety curtains or fences are required - depending on the class of equipment.
If you decide on cobots, check their safety parameters so that they work safely in the immediate human environment.

5. use data from reports and analyses

Document the results achieved in the form of daily or weekly reports.
Conduct periodic analyses to make adjustments and continuously improve the process.

Conclusion: profits in the short term

Properly designed and installed automation of the packaging process can produce clear results in a short time. Companies that have opted for robotisation are reporting, among other things:

• Higher productivity with a lower workload for employees.
• Lower complaint rates due to consistent quality of packaged goods.
• Protecting staff from injury and reducing staff turnover in the packaging department.
• Better competitive positioning through faster and timely deliveries.

Summary

Automating the packaging process can become a turning point for your company in building a market advantage. It reduces costs, speeds up order processing and allows operators in the packaging area to focus on tasks that require strategic thinking or thorough quality control. With a well-planned implementation - even without stopping the entire line - you will gain tangible benefits in a very short time.

If you would like to benefit from professional support for packaging robotisation or other processes related to industrial automation, please see our offer robotisation of packaging. There you will learn how the Michale Automation team combines innovative technology solutions with systems integration expertise to deliver complete turnkey robotic lines and stations.

We also encourage you to check out:
Robotisation of repetitive production - if you are considering further improvements to your factory.
Servicing and maintenance of stations - in order to maintain the ongoing performance of the newly implemented solutions.

Do you have questions? Need a quote or want to consult on your packaging automation idea? Get in touch with us now. Our consultants will be happy to advise you and suggest the solution best suited to your needs. Together, we will plan every step of the implementation so that your company gains long-term benefits and a strong competitive position in the market.

FAQ

How long does it take to implement automation in a company?
The implementation time depends on the complexity of the processes and available resources. It can range from a few weeks for simple solutions to several months for extensive projects and large integrations.

Does automation mean redundancies?
Usually no. Automation allows employees to focus on more creative and strategic tasks, while freeing them from monotonous tasks. Many companies use this to retrain and develop their team professionally.

Does robotisation only pay off for large companies?
Today, advances in technology are leading more and more small and medium-sized companies to turn to robotisation. Costs are coming down and flexible solutions can deliver a favourable return on investment even for smaller operations.