How to improve packaging line efficiency

Whether manual or automated, packaging lines are a critical component of a company's business, encompassing the process that prepares products for shipment to customers and end users. For this reason, lines must create secure and efficient packages to protect goods throughout the supply chain.

The reality is that improving the efficiency of the packaging line is decisive in optimising processes and reducing costs. Let's look at how an operations manager can measure line efficiency and how he or she can improving the efficiency of the packaging line to save time, money and other resources.

What is a packaging line and how can we optimise it?

Packaging lines are the process during which products are placed in packaging materials, such as boxes or sachets, and prepared for shipment. Depending on the specific needs of each company, fillers such as air cushions or foam are also placed in this process to protect the contents. At the end of the packaging line, the package or container is sealed and, if necessary, palletised and unitized with other products before being transported by road, air, sea or rail.

Packaging lines can be fully automatic or manual with operators doing all the packaging by hand. However, most packaging lines are somewhere in between, with a mix of manual labour and automatic machinery. Therefore, understanding the line itself is essential when it comes to determining how to improve the efficiency of the packaging line.

How to measure the efficiency of the packaging line?

As a preliminary to improve the efficiency of the packaging line, it is necessary to  measure their performance. This is a fairly straightforward process, but it is important to pay attention to detail and be realistic about capacities and expectations. Compare planned or desired production with actual production. When determining the planned production, it should be taken into account that each operation is different. If the packaging line is small and fully manual, it will not produce as many packs at the end of the day as a large company with a fully automated packaging line.

When measuring actual production, it will normally be lower than initially expected. If this is the case, it is time to improve the efficiency of the packaging line.

Why do packaging lines slow down?

There are a number of factors that can contribute to a slowdown or stoppage on a packaging line. When examining the efficiency of a line, some key elements that may be causing the slowdown should be considered and it is useful to consider the following questions:

• Are packaging and palletising machines up to date and checked at regular intervals?
• How are consumables stored and are they exposed to humidity or extreme temperatures?

Outdated palletising machinery and damaged consumables are two of the most effective ways to slow down packaging lines. If equipment breaks down, it brings the line to a complete halt while it is repaired or replaced, and delays the shipment of products to customers because there is no way to package them. In addition, damaged consumables can cause significant slowdowns if, for example, corrugated boxes are used and stored in a place with high humidity, as they can end up warping before they reach the packaging line. The truth is that a warped box is more difficult to assemble, regardless of whether a machine or a person builds it.

Tips for improving packaging line efficiency

There are quick and successful solutions for improve the efficiency of the packaging line: 

• Understanding the company's packaging process: For improving the efficiency of the packaging line It is important to understand the packaging process as every company has a different packaging process and system, especially if it is done manually. Manual packaging of products often causes inefficiencies because the failure rate of human error is quite high compared to a machine. Understanding the packaging process is very important to know which parts should be changed to an automatic system as these systems increase efficiency by speeding up packaging time and reducing failure rates.
• Routine servicing and maintenance of palletising machinesThis will keep them running in the best possible condition and drastically reduce the possibility of breakdowns and delays in the packaging line.
• Optimum supply of consumablesBy stocking the right amount of consumables, packaging line stoppages due to material shortages can be avoided.
• Packaging equipment integration and synchronisationIf the packaging line has more than one piece of automated machinery, make sure that they can work together and with the team members to avoid bottlenecks and delays.
• Staff trainingOperators must be given the necessary training to operate all machinery correctly, build all packaging materials and get their products out the door safely and on time.
• Reduce the use of packagingMaintaining product quality and safety during the supply chain is very important because it is directly related to customer satisfaction. Usually, companies provide special packaging to ensure that products are safe and that the shipping process runs smoothly. However, companies have to start replacing traditional packaging systems with automated packaging systems through conveyors that can move products at each stage of the shipment and reduce the risk of product damage.
• Manage and track damage levels during the shipment processDamaged products will reduce prices, customer satisfaction and lead to the return of the goods.

Conclusions for improving the efficiency of the packaging line

All processes in the supply chain are very important, from raw material selection, production, packaging to product shipment. The process of packaging efficiency is very important because if it is disturbed, it causes problems that disrupt the flow of the supply chain.

Companies need to start measuring the problems that occur during packaging, distribution and logistics processes to identify the problem before it escalates and thus minimise costs and energy. Improving packaging line efficiency not only saves production costs in the supply chain, but also brings an increase in service and management. The Collaborative palletising robots to optimise packaging lines are another viable option to improve packaging line efficiency.

Therefore, the implementation of automated processes in some parts of the production chain saves costs, reduces damage levels and increases customer satisfaction.