Upfront costs associated with new equipment and employee training might make some companies wary of adopting automated solutions. However, there can be big benefits to automated packaging — and new technology is making it easier than ever to automate more and more steps of the process.

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Here are five benefits of automated packaging lines.

1. Extra (or Improved) Quality Control.

In the past, automation solutions weren’t always robust enough to fully automate the job of overseeing packaging line quality control. Instead, the tedious and repetitive work of inspecting all items was left to human workers.

With the development of new technology — especially machine vision using artificial intelligence (AI), which allows computers to “see” errors like human workers do — this is changing. The designers of some modern quality control systems are going so far as to say that their systems don’t make mistakes and can catch nearly 100% of errors.

Automated quality assurance (QA) systems also work tirelessly, meaning their ability to catch errors won’t wax or wane over the course of a shift. Coupled with other automated equipment in the packaging process, this can mean highly consistent packaging and longer productive hours.

2. Improved Production Speed.

With the right automation solution in place, it’s possible for companies to significantly improve production speed and product throughput. It’s not unusual for an automated bagging machine, for example, to bag items much more safely and several times faster than the average employee.

Automated packaging solutions can also multitask and fold multiple steps of the packaging process — like sealing and labeling — into one single step. This way, these solutions free up not just one employee, but potentially several. As a result, these technologies can both increase speeds and allow packaging companies to shift their staff to tasks that require human workers or simply benefit from the human touch, like shipping, receiving, and picking.

At the same time, these automated systems can also improve the consistency of packaging and reduce the rate of errors introduced during the packaging process.

While increases in speed vary depending on packaging types and processes, all packaging lines can benefit from the constant output offered by automated systems. This frees up labor on the packaging line, potentially reducing labor costs as well. Automated systems can also be used to more consistently pace the packaging line, which can further boost productivity and profitability.

3. Improved Ergonomics and Lowered Risk of Employee Injury.

In manufacturing and packaging, where it’s common for employees to perform highly repetitive tasks over long shifts, it’s not uncommon for employees to suffer from work-related musculoskeletal disorders (MSDs), sometimes called ergonomic injuries.

These injuries are some of the most common in industry, accounting for one-third of all workplace injuries, according to the Bureau of Labor Statistics. They also typically require more than a week of recovery time.

Reducing the amount of repetitive work that employees need to do can naturally decrease their risk of MSDs. Process automation systems are already a great fit for repetitive or tedious tasks because these tasks often benefit from consistency. By swapping machines out for workers in steps of the process that demand highly repetitive motions, it’s possible to both increase productivity and reduce workers’ risk of injury.

4. Reduced Labor Costs.

Right now, with the unemployment rate reaching historic lows in the US and consumer demand continuing to rise, packaging companies are beginning to feel the effects of an increasingly competitive labor market. Workers have more options for employment, driving up wages and ultimately increasing labor costs.

One possible solution to this problem is automation. By automating as much of the packaging line as possible, companies can ensure that workers are only being hired when they are needed, and then remove workers from the packaging process when they aren’t needed.

5. Improved Information Access.

More and more often, designers of packaging line automation systems are making the design of HMIs (human-machine interfaces) a high priority. These improved HMIs can make it easier for workers and managers to access information relevant to individual machines and packaging line processes.

The pivot to better information access also comes at a time when system designers are focusing less on individual machines and more on turnkey and integrated solutions to packaging line automation. As a result, when workers have better access to information via an individual HMI, they may also have access to data and analytics from the entire packaging process, allowing them to make the most informed decisions possible.

Standardized HMIs also make these machines more user-friendly, reducing the training that workers need to operate them successfully.

Automated packaging lines can offer significant benefits for product manufacturers. By taking on the burden of repetitive and tedious tasks, these systems can reduce the risk of ergonomic injury and shift workers to higher-value tasks where they’re more desperately needed. These systems can also boost productivity and improve quality control measures, all of which translates to improved profitability in the long run.

8 Benefits of Automated Packaging in Factories

Automated packaging solutions can transform your production stream.

Here’s how.

In manufacturing, the focus of automation is often centered on the production and assembly of components into a finished product. However, just as important to manufacturers is the ability to quickly and safely transport those products to their next destination in as cost effective a manner as possible.

In many industries, human operators still play an essential role in this process. However, the work involved is often both laborious and tedious. The strain on workers, both mentally and physically, can lead to greater production errors, delays, and even injury.

Manufacturers can eliminate these risks by turning to automated packaging. With the advanced material handling capabilities provided by cutting edge robotics technology, there are few packaging requirements that can’t be handled by automated processes. Here’s why the investment is worth it.

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1. Improved speed and efficiency.

The most obvious benefit from automated packaging is achieving a greater production rate  than manual packaging. Advanced robot integration and software can perform the same set of programmed motions faster, consistently,  and without risk of injury. And with the high precision of the latest technology means they can safely handle even the most delicate components.

2. Reduced employee injury.

Packaging is hard work, and the job takes its toll on workers in a variety of ways, from those who injure themselves lifting heavy objects, to those who develop repetitive strain injuries from performing the same motion over and over again, to those who struggle to maintain focus after hours on the job. Automating these systems frees employees to take on higher-level tasks, while avoiding the economic impact of injury & lost time

3. Higher quality control and standardization.

When it comes to highly repetitive tasks, humans are more prone to error than automated systems. Manual packaging processes can result in more mishandled or damaged products, or simply a lack of uniformity in the finished packing job. Advanced vision systems, including 3D, also make it easier for robots to spot production anomalies during the packaging process, removing substandard products before they reach consumers.

4. Zero down time.

Automated packaging automation does not need to take a break. Or at least, when maintenance is due, it can be scheduled for a time when it is most effective for the rest of the production stream. With advanced monitoring systems, businesses can also identify when a packaging system may need additional attention, and schedule a maintenance ahead of time instead of being surprised by a malfunction. SmartTrac is an option offered by Eagle that monitors and schedules maintenance schedules, while also providing a path for greater OEE and productivity

5. Fewer bottlenecks.

Manual operators tend to be more or less productive throughout their work shift. A worker may be highly productive when they first come onto a shift or after a lunch break, but slow down toward the end of their shift or when they get distracted. This can lead to situations where the production Is bottlenecked by operators who can’t keep up with the flow of incoming products. Automated packaging systems don’t suffer from fluctuations in productivity, meaning they cause fewer bottlenecks in the production line, & can also handle occasional surges in production which can choke manual processes

6.   Labor

In today’s environment, not only is the cost of labor a key factor,  often the actual availability & retention of labor can be extremely difficult to manage.  High employee turnover adds to inefficiencies, cost, and potentially product integrity.    Also, as we all are facing the current health issues, reducing the number of employees who are working  in close proximity to each other is a need.

7. Greater sustainability.

For years, consumers have been leading a drive toward greener packaging materials. This means that manufacturers who can demonstrate that their packaging follows sustainable practices can win goodwill from customers. Eco-friendly packaging materials are just one part of an environmentally sustainable packaging solution. Packaging processes that cut down on waste can conserve resources, which also save costs for the manufacturer.

8.   Flexibility

Changes in the packaging processes always exist and include production rates, package profiles, new products & configurations, and quality inspections.  The need to provide for efficient change-overs is vital.  Robotic automation provides greater flexibility to manage these changes, and may include simple re-programming, modifications to the end effector, and software interfacing to permit execution of multiple recipes or formats.

Despite the up-front costs, manufactures can recoup their investment within months.

While many manufacturers hesitate over the layout of capital expenditure needed to design automated packaging solutions, the savings from reduced labor costs, higher output, and improved efficiency quickly make these expenses a thing of the past. And these are just the direct benefits. Indirectly, manufacturers have a lot to gain from custom packaging that protects their products during transit, presents a more trustworthy appearance to customers, and utilizes environmentally friendly materials.

At Eagle, we have experience creating custom packaging solutions for manufacturers in a broad range of industries. Our packing capabilities include:

·         Primary Processing :  picking, sorting, placing secondary Packaging :  Carton/case packing, bagging, wrappingEnd of Line Packaging :   Palletizing, Depalletizing, StretchwrappingCustoms :   Kitting, vision inspection, unpack/repack, Conveyors :  Product, parcel, pallet.  Stainless Steel, washdown.  Custom.Systems :   Complete line engineering and integration

Contact us today if you would like to learn more about how our packaging automation solutions can help your business.

Eagle Technologies, headquarters in Bridgman, MI

Eagle builds the machines that automate manufacturing. From high-tech robotics to advanced product testing capabilities, Eagle offers end-to-end manufacturing solutions for every industry.

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