Created on 09.14

Packaging Line Automation: A Pre-Deployment Readiness Guide

Packaging line automation may bring about efficiency, speed, and effectiveness in production, but successful automation cannot be achieved through merely choosing a robot or an automated machine. A complete robotic packaging and end-of-line automation solution should be planned around the overall production flow, layout, product handling, and downstream processes.

Automation fails for many companies since the production environment is not properly set up prior to equipment installation. Factors such as inadequate floor space, instability of upstream processes, frequent product changeovers, incompatible communication systems, or unclear maintenance requirements may all lead to poor results in the automation process.

A solution is to carry out an evaluation of the production environment prior to the deployment of automation.

This guide will give five factors that need to be checked before packaging line automation takes place: production capacity, plant layout, product flexibility, system integration, and operational readiness.

Automatic twin-axis case packing robot integrated with conveyor system for packaging line automation

1. Determine the Real Production Requirements

Before planning an automated packaging line, it is important that the manufacturer have knowledge of the current production system.

First, find out about the real operational requirements instead of just focusing on the production targets.

Key information should include:

Current production speed
Target production speed
Product dimensions and weight
Packaging formats
Case or carton specifications
Number of SKUs
Product changeover frequency
Operating hours per shift
Number of production shifts
Existing equipment capacity
Current production bottlenecks

For example, a packaging line may have a high-speed filling machine upstream, but if the existing case packing or palletizing process cannot maintain the same production rate, the packaging area can quickly become a bottleneck.

This is why automation of the packaging line should take into consideration the entire production process and not one specific machine.

Think Beyond Maximum Speed

Maximum speed is one of the main characteristics of machines, but maximum speed doesn't necessarily reflect the capacity for sustainable performance in production.

When planning for automation, keep in mind:

Normal speed of operation
Time for product accumulation
Time of changeovers
Machine downtime
Product rejection rates
Operator involvement
Maintenance time

A system that works perfectly in a short-term production trial may find itself unable to produce the needed number of products during a regular production shift.

In other words, the target is to define a realistic range of operations for the entire line.

2. Factory Layout Prior to Equipment Design

A factory layout is yet another important thing to consider when automating packaging lines.

The automated system requires sufficient space not just for equipment but also for conveyors, safety guards, operator access points, maintenance space, material movement, and electrical connections.

Before designing the automation system, make sure to review:

Floor space available
Height of the equipment
Routing of conveyors
Direction of product infeed and outfeed
Access points for operators
Maintenance access points
Material movement paths
Safety zones
Emergency exits
Utilities available
Expansion space required in the future

Look at the Full Equipment Footprint

One error is taking into account only the footprint of the robot or packaging machine alone.

For instance, when considering a robotic packaging system, it will need conveyors, equipment for handling the products, control cabinets, fencing for safety, sensors, and space for accessing equipment.

Such elements may have a huge influence on the amount of floor space needed.

An effective layout analysis should take into consideration the whole automation cell, not each machine individually.

Plan for Maintenance Access

Maintenance access planning should be done during the design phase and not during the installation phase.

Maintenance technicians might require access to motor assemblies, sensors, control panels, pneumatic assemblies, grippers, conveyors, and many other pieces of machinery. This access should also be considered from a safety perspective, as maintenance and blockage clearing may require personnel to work around moving equipment such as conveyors and palletizing systems. For practical packaging machinery safety guidance, manufacturers can refer to packaging machinery safety guidance.

When the maintenance area is too limited, even simple inspection might lead to more downtime.

An efficient layout should allow enough space for maintenance and operations to be done efficiently without affecting the remaining production line.

3. Assess Product & SKU Variability

Product variability can play a very significant role in the design of automation on the packaging line.

An automated production line that handles only one stable product form may need to be designed in a completely different way than an automated system handling several SKUs with different sizes, weights, packaging materials, and cases.

Before the process of automation begins, determine the degree of variability of your products during the production run.

Think about:

Dimensions of the product
Weight of the product
Shape of the product
Packaging material
Dimensions of the case
Orientation of the product
Number of SKUs
Changeover rate
Future product introduction

Changeover Plan

Changeover considerations become even more crucial for those companies producing more than one SKU.

While one SKU may operate well on an automated system, another might cause difficulties without substantial manual input.

When designing the system, identify all the components that can be potentially modified or replaced. For case packing applications, equipment such as twin-axis case packing robots can be configured with different gripping solutions to accommodate different product formats. Other components that may require adjustment include:

Grippers
Guides
Conveyors
Sensors
Product positioning systems
Case handling systems
Robot programming

The goal is not to remove every single modification from the process.

Rather, the system needs to have a reasonable and replicable changeover procedure.

Think of Future SKU Growth

Automation projects typically run for many years.

If the business anticipates launching new products or new package sizes, those needs should be addressed ahead of time.

An automation solution that is built strictly to meet current production needs may prove limiting as the SKU growth occurs.

4. Confirm Communications and Interface Needs

Automation in the packaging line is usually not an independent system.

A robotic case packer, palletizer, conveyor, sensors, packaging machine, inspection machine, and production control system might all require the transfer of information.

Communication needs for each component must be identified prior to installation.

Important considerations include:

PLC architecture
Control system compatibility
Sensor interfaces
Communication protocols
Product tracking requirements
Machine status signals
Fault signals
Start and stop commands
Safety interlocks
Data collection requirements

Define What Happens During a Fault

Integration should not only be considered when everything is operating normally.

Manufacturers should also define how the system responds when a machine stops, a product is missing, a case is incorrectly positioned, or a downstream process becomes unavailable.

As an example, if the case-packing robot stalls due to a malfunction, then the upstream conveyor might have to slow down or stop. Likewise, if the palletizing area is full, then the upstream equipment will need to be notified.

These situations should be taken into account during system design.

An ideal packaging line would be one where the equipment could work in synergy with each other and not as standalone automated systems, which need operator supervision at all times.

Integrated robotic packaging and palletizing system with conveyors

5. Planning for Operational Maintenance Over the Long Run

The installation of automated systems is just the start of the process.

Long-term success will depend on maintenance procedures, parts availability, operator training, technical assistance, and rapid problem identification.

Prior to implementing, consider:

Required maintenance schedules
Parts needed
Availability of spare parts
Operator training needs
Maintenance training
Troubleshooting procedure
Software and control system support
Technical assistance remotely

Identify the Most Critical Components

Not all components have an equal effect on manufacturing.

It is advisable for manufacturers to find out which components would lead to long downtimes if they break down.

They might include:

Components of robots
Servo motors
Sensors
Pneumatic components
Conveyor systems
Grippers
Controllers
Safety components

It will be easier for you to prepare for maintenance and spares by knowing all these components beforehand.

Plan Operator Training

Automation is not going to make skilled workers unnecessary.

The operators might require training in machine start-up, changeover of products, troubleshooting of faults, and other safety aspects.

There might be a need for maintenance staff to undertake training for repair work in mechanical, electrical, robotic, and controller systems.

Training needs will therefore need to be included in the implementation plan.

Pre-Deployment Practical Checklist

Prior to starting your packaging line automation project, consider the following questions:

Production Readiness

Do we have the actual production rate, rather than just our target rate?
Are all the existing bottlenecks known?
Is there sufficient data on production that we can use to determine our automation needs?

Layout Readiness

Do we have sufficient space to accommodate the automation cell?
Do we have sufficient space for operators and maintenance?
Does our layout allow for efficient material movement?

Product Readiness

Have all current SKUs been identified?
Are product and case dimensions defined?
What is the frequency of change in products?
Is the future product format expected to be accommodated by the system?

Integration Readiness

Are communication and control needs defined?
Can upstream/downstream machines communicate required signals?
What must be done when a machine goes down or downstream processes are unavailable?
Are requirements for product tracking and production data defined?

Operational Readiness

Are maintenance procedures defined?
Are required critical spares identified?
Does operator/maintenance staff training need to be added?
Will there be post-installation technical support?

If many of the above cannot be answered at this time, then additional work may be needed before equipment specification.

From Automated Machinery to a Fully Integrated Packaging Line

Effective implementation of an automated packaging line requires more than the capability of the individual robotic or packaging machines.

A fully integrated packaging line must consider the products, packaging forms, production goals, facility design, existing machinery, operators, and maintenance activities.

This consideration is especially vital for the inclusion of case packing, palletizing, conveyance, and handling operations, among others.

Rather than just asking, "What machine should we use?" it would also be wise to ask:

Is our production process ready for automation?
Will this system integrate well into our facility?
Is it able to cope with our variability in products?
Will it integrate seamlessly with other machinery?
Are our people capable of operating and maintaining the system?
Will this system support future production needs?

Thinking about such issues before implementation may help avoid many problems.

Conclusion

Automation of packaging lines can offer substantial gains in efficiency, consistency, and control, yet these gains rely heavily on good preparation.

Good preparation requires awareness of production needs to be followed by proper layout design, product evaluation, integration of processes, maintenance preparation, and operator training.

Through completion of the pre-installation readiness check before the equipment is finished, manufacturers will have more time to solve any possible issues and construct an automation system that fits production conditions much more accurately.

When considering new automation for their packaging lines or an upgrade of the current production process, manufacturers should first perform a comprehensive assessment of the whole production cycle.