Packaging systems - the key to efficient and safe shipping

Estimated reading time: approx. 8 minutes

TL;DR:

• Packaging systems protect products and increase productivity
• It is worth adapting the solution to the scale and type of production
• Automation streamlines the process and reduces human error
• Avoid delays and downtime through integration with the production line
• Service support is the key to continuous operation of the entire system

Table of contents

• What packaging systems are and why you should invest in them
• Types of packaging systems - overview of solutions
• Key benefits of implementing modern packaging solutions
• Integrated packaging systems in practice
• Examples of industries and processes that require efficient packaging
• How to choose the right packaging system
• Michale Automation support in the area of packaging systems
• Summary and recommendations

Introduction

Packaging systems are one of the cornerstones of modern logistics and production. Effectively protecting a product from damage and ensuring that it is quickly prepared for dispatch is nowadays crucial not only in the e-commerce or food industry, but also in the engineering industry and many other sectors. Good 'packaging' translates into less quality loss, more efficient transport and greater customer satisfaction.

In this article, we explain how modern packaging systems work, why they are so important for companies of all sizes and how they can be integrated into production lines, including automation or robotisation systems. The article is particularly aimed at process managers in manufacturing and logistics companies who are looking for effective packaging solutions.

Find out how to plan the packaging process in practice, which systems to choose and how to avoid mistakes. You will also learn about example applications and how Michale Automation supports companies in building machines, packaging lines and complete production stations.

What packaging systems are and why you should invest in them

Packaging systems are all devices and procedures that enable products to be secured in packaging (e.g. cartons, crates or containers) and prepared for transport. In most companies, packaging is a repetitive process and, if not properly organised, can affect delivery delays or increased storage costs.

From the point of view of production or logistics managers, computerised and robotic systems are an opportunity to reduce expenditure on manual labour while increasing packaging efficiency. It is also a way to increase quality - the risk of products arriving at the customer damaged will be significantly lower. It is for this reason that large industrial plants often use fully automated packaging lines, while smaller companies opt for semi-automated, employee-assisted systems, for example.

Types of packaging systems - overview of solutions

Depending on the needs and nature of the products, different variants of machines and tools are available. Below are the most popular categories.

External packaging systems

One of the basic elements of a packaging system are solutions for strapping, foiling or banding (securing with tape) parcels and pallets. These can include:

• Tensioners for belts - manually operated or fully automatic machines that tension and seal PET tapes, for example.
• Pallet wrapping machines - equipment that wraps the pallet in stretch film, stabilising the contents and protecting them from moisture or dirt.
• Sealing and binding machines - automatically apply tape or shrink wrap to the parcel.

Systems for filling and securing the inside of a consignment

In addition to external stabilisation, it is extremely important that the contents of the consignment are adequately protected 'from the inside'. The following, among others, are used for this purpose:

• Paper fillers - an eco-friendly alternative to bubble wrap, perfect for companies promoting a sustainable approach to the environment.
• Mouldable foams and inserts - allow the shape of the filling to be adapted to the individual product.
• Specialised moulds (e.g. air fillers) - automated equipment creates the filling in real time.

Automatic and semi-automatic packaging lines

In companies with large-scale production, integrations of packaging lines with assembly tables, conveyors and robots are becoming particularly important. The system often assumes:

• Internal transport of goods (conveyors, belt conveyors).
• Automated packaging station (with robot manipulating the product or paper insert).
• Unit for final parcel sealing and printing of the order data label.

This integrated approach reduces overall order handling time. The packaging process is precise and the risk of error is low.

Key benefits of implementing modern packaging solutions

Reduction in human error and labour costs

Manual packing by employees is fraught with the risk of mistakes and does not always ensure reproducible quality. Automatic systems, on the other hand, operate 24/7, which increases productivity and reduces labour. In one or two years' time, such a model can translate into a noticeable drop in production costs and fewer complaints.

Speeding up and standardising the process

Modern packaging systems make it possible to produce consistent, standardised packaging. Products arrive in a predictable timeframe and, thanks to automation, the speed of handling increases even during peak seasons (e.g. before Christmas).

Image enhancement and impact on customer satisfaction

Packaging still remains the business card of a company. A carefully packaged parcel looks more professional, which translates into customer feedback. Durable, tailored protection increases their confidence and the chances of a repeat purchase or positive review on the internet.

Integrated packaging systems in practice

Plan according to production profile

Before investing in full automation or purchasing packaging machines, it is worth analysing the type of products and their dimensions, shapes or sensitivity to shocks. In some plants, simpler semi-automatic systems are sufficient, while in others, full integration with the production line and ERP system is sufficient.

Implement industry-specific solutions

- The food industry places a strong emphasis on hygiene and packaging safety. Here, environmentally friendly fillers and stainless steel equipment will be key.
- The cosmetics industry requires aesthetically pleasing packaging and often personalised solutions to stand out in the market.
- The furniture industry works on large formats and needs laser-cut film or special cardboard fillings.

Apply packaging robotisation step by step

Many entrepreneurs wonder whether to introduce full robotisation straight away, or whether improvements to manual packing will suffice. In practice, a mixed approach tends to work best for medium-sized companies - some areas of packaging should be automated first (e.g. palletising or filler insertion), while others should remain semi-automated. Before implementation, it is worth doing a process audit and planning the investment gradually.

Examples of industries and processes that require efficient packaging

Furniture industry and large formats

Furniture manufacturers store and transport items of varying sizes - tables, cabinets, MDF boards. It is important here to use robust packaging to prevent scratches or bruises. Packaging processes usually have to be integrated into the production line.

Food industry and safety standards

Food packaging requires great attention to hygiene. Special packaging lines ensure sterile conditions on the one hand and speed on the other, allowing greater throughput. Paper fillers are suitable here for ready-made parcels (e.g. teas, sweets), but in the case of fresh or frozen products, packaging made of food-grade plastic is often used.

Mass production and repeat runs

In plants producing large quantities of identical items (e.g. electronic components, small accessories), speed and repeatability are of paramount importance. Here, fully automated packaging lines can operate without an operator, and every package looks and is secured in the same way.

How to choose the right packaging system

Define technical requirements

Start by determining the size, weight and sensitivity of the goods, as well as the volume of shipments. Determine whether you plan to increase production capacity in the near future. Consider whether the packaging system can be expanded in the future, e.g. with additional foiling or labelling modules.

Assess the return on investment (ROI)

The cost of purchasing packaging machines and robots may seem high, but in large and medium-sized companies the ROI from automation can appear after only a few months or so. If you are unsure, you can make an initial estimate of cost-effectiveness based on data on the number of damaged shipments or manual labour expenses.

Check service facilities and supplier support

No less important than the technology is the readiness of the service to respond quickly. Remember that downtime in the packaging line can generate high losses. It is therefore advisable to use companies that offer a comprehensive service and an experienced service team.

Michale Automation support in the area of packaging systems

Michale Automation has been building machines and production lines and implementing robotic workstations in companies for years. If you are interested in solutions for even more efficient packaging, our engineers and consultants will be happy to assist you at every stage of implementation:

• Project - together we define the scope and expected parameters of the system.
• Construction - we create equipment or complete packaging lines tailored to your production.
• Integration - We combine packaging solutions with an existing production line, ERP or MES system.
• Service and maintenance - we guarantee regular maintenance and a rapid service response, which minimises the risk of downtime.

We use the latest industrial automation technologies in our projects. We are also an official distributor of SIASUN robots, which gives us access to advanced robotic units ideal for packaging robotisation processes (see more on offer Robotisation of packaging).

It is also worth exploring our wide range of services in the field of mechanical engineering, integration and industry support - for details see here.

If, on the other hand, you need regular maintenance or specialist technical support, we invite you to take a look at the service and maintenance offerings.

For many industries, the automation of repetitive tasks is particularly useful. If you are considering introducing industrial robots for packaging or other activities, see also Robotisation of repetitive production.

Summary and recommendations

Highlights and tips:

• Packaging systems make a significant contribution to productivity and quality: they speed up order handling, help avoid damage in transit and allow a rapid response during periods of peak demand.
• Choice of solution should take into account the scale and type of production: You can bet on simple systems (e.g. manual tensioners, paper fillers) or highly automated packaging lines with industrial robots.
• Good integration with the production environment safeguards against downtime: It is worth considering full communication with ERP/MES systems or combining several machines in one line.
• High-quality service is a guarantee of continuous operation: Carefully verify that the supplier provides the necessary maintenance and inspection support.
• Ecological paper fillers can significantly reduce the environmental impact while emphasising the company's green image.

We encourage you to consider implementing modern packaging systems and automating these activities, which also bring long-term savings. If you have any questions or concerns, please do not hesitate to contact automation and robotics specialists.

Summary
Packaging systems are not just about equipment and procedures - they are a strategic investment that translates into customer satisfaction, company profitability and market image. In an age of automation and increasing customer demands, speed, precision and safety are of paramount importance. Therefore, it is not worth leaving packaging to chance - a properly planned and implemented process eliminates complaints problems and improves the bottom line.

If you want to learn more about the practical application of packaging systems or need help implementing a bespoke solution, take a look at the Michale Automation blog or contact our advisors. Feel free to comment and share your own experience in the area of packaging. Share the article with your friends who are facing a similar challenge! Good luck in improving your packaging processes!

FAQ

How long does it take to implement a packaging system in a company?
Implementation time depends on the scale of automation and the level of integration with existing processes. It can be implemented in a few weeks for simple systems or in a few months for more extensive projects.

Will automated packaging systems replace workers?
Typically, automation supports the work of the team and allows employees to be delegated to more creative tasks. These systems reduce monotonous physical effort and minimise errors, but do not necessarily mean redundancies.

Are modern packaging systems only a solution for large companies?
Today, investment costs in automation are falling and solutions are increasingly flexible. Therefore, also small and medium-sized companies can introduce packaging systems with a favourable return on investment.

Can packaging systems be integrated with industrial robots?
Yes, there is an increasing use of robotic stations in packaging lines. Robots can be responsible for manipulating products or fillers, further increasing the efficiency and precision of the process.