The Ultimate Guide to Choosing security bag making machine

Are you struggling with finding an efficient and reliable powder packaging solution?

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Packaging flowing powder requires auger or gravity fillers. In contrast, you need volumetric or paddle fillers for non-flowing powder packaging. That’s why you must choose the powder packaging machine based on your applications, such as food, medicine, or industrial.

With my 20 years of experience in this field, I’m here to guide you in picking the best powder packaging machine. So, let’s begin-  

What Is a Powder Packaging Machine?

The powder packaging machine automatically packs the powdered items into cans, bags, bottles, pouches, and other types of containers. 

The key functions of these machines are filling, sealing, labeling, and weighing the powder quantity of each packet. These machines are used in different industries to ensure hygiene and efficient packaging. You will find them in manufacturing factories of food, medicine, cosmetics, etc.,  that produce powdered products. 

Basic Parts Of Powder Packaging Machine 

1. Hopper

Hooper is the large funnel-shaped container at the top of the machine. It contains the powdered product that goes through the packaging process. You can detach this part to insert/shift products or for cleaning. 

2. Fill Heads

The bottom of the hopper is attached to the fill head. It dispenses the powder from the hopper to the packets or containers. Based on the machine type, the fill head can be of two types: auger and volumetric. 

3. Level Control- Sensors

Level-control sensors detect the quantity of powder inside the hopper. It gives refilling alters when the powder level is low. Thus, it maintains the continuity of the packaging process. Similarly, it notifies you when there are overfilling issues. 

4. Agitator Blades

Agitator blades are stainless blades used to keep the powder inside the hooper in motion. It prevents powders from clogging. These blades can be of different types- flat blades, paddle blades, ribbon blades, or sweeping blades. 

5. Auger

The auger is a spiral-shaped component that transfers the powder from the hopper into the packaging container, ensuring accurate filling. You can adjust the speed and direction of the auger’s rotation based on requirements. 

6. Control System

The control system of the powder packaging machine contains the following-

1. Programmable Logic Controller (PLC)
2. Servo motor
3. Human/Machine Interface (HMI).

The PLC acts as the brain of the machine. It manages various machine functions such as filling, sealing, weighing, and safety monitoring. The servo motor is also controlled by the PLC to ensure precise motion. 

The HMI is a touchscreen display that monitors the machine. It provides real-time data on machine performance. 

7. Dusting Unit

The dusting unit minimizes dust generation during the filling process. An enclosed dusting hood is attached to the powder filling station. As the powder is transferred into the packets or containers, it captures the flying dust particles. This can be later reintroduced into the filling process. Thus, you can reduce production waste. 

8. Conveyor Unit

The conveyor unit acts as a moving platform, ensuring a continuous flow of packaging materials. It carries the empty containers, bottles, or pouches from the infeed area towards the filling stations. Conveyor units can be of several types, such as

• Belt conveyor
• Bucket conveyor
• Screw conveyor.
• Vibratory conveyor 

How Does Powder Packaging Machinery Work?

• Firstly, you need to put the powder into the hopper and position the empty packets/containers of the packaging on the conveyor belt. 
• The conveyor will place the containers under the filling head attached to the hooper. 
• The machine measures the filling quantity and dispenses the powder into the packet/container. 
• The filled containers are then transferred to the sealing station.  
• Once the container is sealed, they are sent for labeling. 

Type Of Powder Packaging Machine

Powder packaging machines can be classified into different types. These are as follows- 

Based On Automation

1. Manual Powder Packing Machine

Manual powder packing machines are manual devices, also known as hand-held machines. It has a handle to rotate to fill the powder containers. This kind of manual powder filling machine requires a lot of manual labor. However, it is cost-effective and good for small, home-based businesses. For example- you can use them as a powder masala packing machine or wet flour packing machine.

2. Semi-Automatic Powder Packing Machine

In semi-automatic powder packing machines, the filling task is automated, but other segments are manually operated. For instance, you need to fill the hopper, adjust the packets, or move them once filled. Therefore, a technician is required to operate the machine. You can purchase a semi-automatic powder-filling machine on a limited budget. 

3. Automatic Powder Packing Machine

Automatic powder packaging machines are fully automated devices. You don’t need any manual function to operate the device. It has sensors to detect product quality. Thus, the hopper filling procedure is also automated. 

These machines are excellent choices for large-scale production. All you need to do is provide data to the device with appropriate parameters and it will do the rest on its own. 

Based On Design 

1. Inline Powder Packing Machines

In inline powder packing machines, the process starts and ends in the same line. Here, filling, sealing, and packaging occur in a linear direction. These types of machines occupy large spaces but have maximum visibility for inspection. 

2. Rotary Powder Packing Machines

Rotary powder packing machines use a rotary mechanism. In these machines, containers are filled, sealed, and labeled in a circular motion. It has a compact design, occupying little space. You will get one of the top four feeding lanes in rotary powder packing machines. So, these are ideal for large-scale productions.

Based On the Packaging Solution 

1. Automatic Can Powder Packaging Machines

Automatic can packaging machines are designed to fill powders in jars, cans, and bottles. They use a screw-type mechanism to dispense the powder into the cans. If you are working with free-flowing powders, automatic can powder packaging machines are a good option. They require no manual labor to fill or seal the cans after filling.

Based on packing style, automatic can powder packaging machines are composed of components such as powder filling, sealing, capping, and labeling machines.

2. Powder Form Fill Seal (FFS) Machines

Form Fill Seal (FFS) machines fill powder, creating bags/ pouches from a roll of film. These machines can be of two types- 

1. Vertical Form Fill Seal (VFFS) Machines

Vertical Form Fill Seal machines use film sheets to produce tube-like packaging bags. They take up little space for their vertical design and are ideal for small floor areas. These machines can be of different types based on packaging style- 

• Pillow Powder Packing Machine

As the name suggests, these machines produce pillow-shaped packages. These are sealed from three sides. Pillow powder packing machines are widely used to pack powdered milk, coffee, flour, etc. 

• Sachet Powder Packaging Machine

These machines produce small, single-use packets or sachets. They should be used for packing small-quantity powder products. Sachet packaging machines can be used for both flowing and non-flowing powders. You can use these machines as small spice packing machines or milk powder packaging machines. 

• Stick Powder Packaging Machine

The stick pack machine is a versatile option for packing single-serve products. It produces three-sided sealed long narrow packs made of plastic, aluminum, or paper, suitable for nutritional powders, instant coffee powders, spices, etc.

2. Horizontal  Form Fill Seal (HFFS) Machines

A Horizontal Form Fill (HFFS) packaging machine uses film rolls to produce packets for filling powders. These films move in the horizontal direction, which is why they are known as HFFS machines. Here, packet manufacturing, filling, and sealing occur within a single machine.

3. Premade Pouch Powder Packaging Machine

Different from roll forming, premade pouch packaging machines use pre-made pouches, offering a more modern and convenient powder packaging solution. These machines use premade pouches to fill powders in various styles, such as doy-pack, quad, stand-ups, 4-side seals, etc. 

Things To Know To Choose The Best Powder Packaging Machine 

Note down some facts that you must consider before purchasing a powder packaging machine: 

Determine The Powder Type: Free-Flowing or Non-Free-Flowing 

Powder can be of two types: free-flowing and non-free-flowing. Free-flowing powders such as sugar and salt do not get sticky. On the other hand, powder that tends to stick together is called non-free-flowing powder. The filler type of the powder packaging machine differs for free-flowing and non-free-flowing powders.

Bulk Density

Calculating the bulk density of the powder is essential to determine the ideal pouch size for the powder. It determines the compressibility and flowability of powder under pressure. 

But how to determine the bulk density of powder? 

The formula for bulk density, (ρ)  = M / V

Here, 

ρ = Bulk density (g/cm3) 

M = Mass of the powder (g or kg)

V = Volume of the powder (cm³ or m³)

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High-bulk-density powders generally take up less space than low-bulk-density powders. For example, brown sugars or sands are high-bulk-density powders. They can be easily compressed. So you can fit them into small pouches. But low-density powders like roasted coffee don’t compress much. They are to be packed in larger pouches. 

Besides, flowability is also a crucial factor here. Even with similar bulk densities, free-flowing powders will naturally pack denser than non-free-flowing powders.

Installation Space: Machine Size 

You must consider your factory’s area and vertical space size to pick the right machine size. HFFS machines or in-line machines take up large spaces. Meanwhile, VFFS or rotary powder packing takes up less space than other variants. So, if you have a small production area, go for these machines. 

Bag/Container Style  

Powders are filled in different types of powder packaging bags or pouches. And the machine type differs for the style of bag you use. For example, for single-use packs you will need powder sachet packaging machines. Whereas for bulk packaging powder box packaging machines are essential.

Therefore, you should first decide what type of bag you want to pack the products in, then decide on the machine type. The chart below will help you with selecting the right powder bag filling machine- 

Production Capacity To Determine Packaging Speed 

 The speed of a machine is the number of packets it can fill in a minute. It is calculated as Packs Per Minute (PPM), which helps you track the machine’s daily production capacity.  

You will find the production capacity in the machine’s manufacturer specification. A small-size powder packaging machine has a lower production capacity. Calculate your daily production requirement and purchase one accordingly. The chart below gives you an idea about the industrial production capacity of powder packaging machines: 

Construction Material

Powder packaging machines are made of stainless steel, aluminum, carbon steel, plastic & polymers. Among all these construction materials, stainless steel machines are the most durable. Though expensive, they are best for industrial-level production. 

Specific Requirement Based On Industrial Application

Medicinal Powder Packaging machines must adhere to Good Manufacturing Practices (GMP) regulations. This ensures product safety and quality.  Again, if the machine is for food-grade powder packaging, it must meet strict hygiene standards like the FDA and USDA. So, before you purchase any machine, research industrial standards. However, always look for a fully automatic filling and sealing machine for bulk production. 

Price

Look for quality powder packaging machines with better brand value. Don’t always look for a low cost powder filling machine. Before purchasing any devices, do a competitive price comparison. Also, long-term cost-effectiveness and spare part availability should be considered. 

Warranty 

A good warranty policy ensures the security of your investment. You should purchase from powder filling machine manufacturers that offer extended warranty facilities. Also, check the company’s presale and post-sale services. 

Installation Of Packaging Machine For Powder 

Step 1: Site Preparation

Decide on a space where you want to place the powder packaging machine. Make sure the space is well-ventilated and dry. Also, consider a level floor that can support the machine’s weight. 

Step 2: Unpacking and Inspection

Use a lifting tool to unpack the machine with care. Look for any missing or damaged parts. If you find any issues, immediately contact the supplier or packaging machine manufacturer.

Step 3: Positioning the Machine

Move the machine to the selected location, ensuring leveled placement on the floor. Use lag bolts to secure the device on the ground firmly. This will prevent unnecessary movement of the machine while operating. 

Step 4: Electrical and Pneumatic Connections

Connect the machine to the power supply following the manufacturer’s instructions. Ensure the machine and power source are voltage-compatible. However, if it requires a compressed air supply, connect the device to a pneumatic system.

Step 5: Initial Setup and Calibration

Adjust settings such as fill weights, sensors, and machine control systems. Also, the rotation of the motors must be fixed. The filling motor must be directed counterclockwise. In contrast, the agitator motor should be directed clockwise.

Step 6: Test & Run

Power on the machine and text if all the parts are moving correctly. You can do a small test run to optimize performance by filling the hopper with powder and snake adjustment. Also, check for consistent filling and sealing, as well as any signs of clogs or leaks. 

Troubleshooting Powder Packaging Machine 

1. Dust Issues

Dust generated during packaging can cause health risks and affect product quality.

Solution: 

• Purchase machines with built-in dust control systems, such as dust collection bags. 
• Ensure the packaging area is well-ventilated. 
• Wear appropriate personal protective equipment (PPE) like respirators. This will minimize inhalation of dust particles.

2. Material Flow Problems

Powders with varying bulk densities cause flow issues. This leads to inconsistent filling and operational disruptions.

Solution:

• Choose a machine suitable for the bulk density of your powder.
• Use a hopper vibrator or pre-compression box to promote material flow.
• Adjust product temperature and humidity levels to improve powder flow.

3. Sealing Issues

Inappropriate sealing lets air enter inside the packaging. This damages the product and lowers its quality. 

Solution:

• Ensure accurate seal temperature and pressure.
• Consider packaging material and powder type to pick ideal sealing materials.
• Regularly inspect sealing components.

4. Frequent Clogs or Leaks

Clogs in the feed mechanism hinder the production flow. On the other hand, leaks in packaging lead to product wastage. It also creates hygiene issues. 

Solution:

• Clean and inspect feed mechanisms regularly.
• Minimize pressure levels
• Use filters and screens to prevent foreign particles from entering the packaging system.

5. Inconsistent Filling

Variations in powder density or improper machine calibration can cause inconsistent filling. 

Solution:

• Consider advanced weighing or volumetric filling systems 
• Monitor and adjust machine settings regularly

Powder Packaging Machine Maintenance Tips  

1. Clean the machine regularly to remove dust, debris, and residual powders.
2. Check seals, gaskets, and joints for wear or leaks.
3. Lubricate moving parts to prevent friction and wear. Use appropriate lubricants for food and pharmaceutical powder packaging machines. 
4. Regularly calibrate the weighing system for accurate packaging quantity. 
5. Replace worn-out or damaged parts.

Future Trends in Powder Packaging Technology

• More automation features will be available for the powder-filling process. This will enhance the accuracy and effectiveness of powder packaging machinery
• Real-time monitoring features will be invented to monitor the powder condition. 
• Artificial intelligence will make maintenance and operations much easier.
• More energy-efficient and cost-effective solutions will evolve. 
• We will find extensive flexibility and a machine customization facility.

Wrapping Up

Always consider the industry-specific requirements and powder type for the best powder packaging machine. Production capacity, bag style, powder’s bulk density and installation are also essential factors. But whatever machine you purchase, always give preference to brand reputation. For this, the Honor Pack powder packing machine is your go-to solution!

FAQs

What are the advantages of a powder packaging machine?

Powder packaging machines provide a quick and effective solution to the powder filling system. They also maintain consistency and accuracy and reduce manual labor. 

How much does a powder packaging machine cost?

The price of powder packaging machines differs depending on their type, production capacity, and features. For instance, an automated machine can range from $20,000 to $100,000+. On the other hand, manual powder packaging machines cost between $1,000 and $5,000.

How do I prevent clogs or leaks in my powder packaging machine?

Use a hopper vibrator to prevent feed clogging in the powder packaging machines. However, to prevent leaks, check the feed rates and pressure levels. Also, look for unwanted substances in the feed or machine that can cause leakage.  

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:

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• 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

○ 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.