Fundamentals of Packaging Machinery
Designing the perfect packaging machinery means taking into account a multitude of different factors, from size and shape to speed and efficiency. It can be overwhelming – but with the right considerations, you’ll find yourself on the road to creating packaging machinery that works wonders! Let’s take a look at some important design considerations for success.
Types of Packaging
When selecting the packaging machinery for your product, one of the key things to take into consideration is the type of package you need. Generally, packages are divided into three main categories: primary package, secondary package and tertiary package.
The primary package is often referred to as the consumer package and involves goods that are intended for immediate sale or use by end-users. These may include items such as bottles and jars that contain food products or products like soaps and shampoo. In some cases, it could also include items such as bags or box packaging that protect goods during storage and shipping before they reach end-users.
The secondary package is usually used for short-term storage and transportation purposes and in many cases will be recycled after use. This type of packaging offers effective protection during distribution from manufacturing points to warehouses. Typical secondary packing will involve boxes or cartons with additional support layers added, such as foam or cardboard inserts that provide cushioning for fragile products or expandable packing peanuts for insulation of liquid containers against temperature changes.
The tertiary package (sometimes referred to as a palletizing unit) is a large, multi-layered system designed mainly for long-term storage purposes which add a further layer of protection over both primary and secondary packages while explaining them together securely on a larger platform making it easier to transport in bulk volume over long distances with ease. Depending on configuration you can have anything from standard pallets all the way up to custom crates, drums and containers using built in strapping tooling machines such as automated strapping systems which secure packages together on an automated basis ready for transport within vastly reduced timeframes over manual processes
Packaging Process
Packaging is an essential component of sustainable and efficient business operations. Properly designed and integrated packaging machinery can reduce costs, improve efficiency, reduce product waste and minimize factory-floor disruption.
Types of Filling Machines
When performing a packaging process design, there are four primary sections to consider: the filling section, sealing section, labeling and end-of-line section. Each has an important role in the effectiveness of the resulting system.
The filling section is responsible for getting the desired product into proprietary packages while avoiding leaking or contamination. Equipment used includes unscramblers, fillers and deposit blanking systems. Unscramblers are generally used to feed various products into the filler based on individual demand type whether solid or liquid products may be filled by a volumetric or gravimetric device depending on application needs. Deposit blanking systems are then often employed to promote faster throughput of finished packs from the packaging system and may include multi-lane programs with increased speed capabilities so that large amounts of product can be filled with greater efficiency.
Once filled, a packaging process will require a mechanism for sealing each package’s contents before labeling or further processing occurs; this is handled by the sealing section which utilizes specialized machines such as vacuum sealers, heat sealers or band sealers to neatly close packages at a rate suitable for packers’ needs. Vacuum sealers use vacuum pressure environments with atmospheric gases to create hermetic seals whereas heat sealers require heated blades to melt sealed container surfaces together creating firm seals that protect their contents from external contamination; band sealers ensure bags remain closed effectively creating airtight bonds while helping increase throughput speeds as they do not require bag cooling time after being sealed like other machines do; this technique is often beneficial when attempting to handle fragile items such as powders inside bags because mismatching closures leave products safely packaged along longer distances during transport times as opposed to some other methods like heat/vacuum sealing where certain constraints apply leading seals misaligning due to temperature restrictions placed on them during welding processes which would ultimately result in issues downstream if not addressed properly beforehand . Additionally it’s important that all designs take into consideration irregular shaped containers when selecting equipment types for maximum closure efficiency – once done correctly higher output capacities can be achieved even if working with smaller size pack formats ensuring quick turnover times within production lines across many industries
Finally labels need to be attached using either automatics label applicators or manually depending on load requirements per shift – automatic applicators provide reliable accuracy at ever increasing speeds making them ideal choices when handling large orders as system throughput times could potentially double given proper settings have been configured ahead . However manual labelling still exist today amongst many companies because some items cannot tolerate automated processes while still maintaining external look quality standards therefore remains necessary even though labour demands may increase slightly along decreased overall production efficiencies due lack of automation implementations assembly lines relying solely manual interventions making it an ideal choice those companies whom cannot absorb additional capital costs associated automated engineering solutions meaning they prefer savings area instead investment ones leaving balance between two approached up customers/industry/company specific requirements spending considerations where odd cases experienced independent nature particular outcomes desired within respective industry sector prior any implementation strategies run evaluate various ways get greatest return limited cash investments available current landscape faced job being performed individually facility basis optimize operations over long run ensuring sustainability long term success all feasible approaches taken account
The variety of products being packaged and the different forms they come in has resulted in many types of filling machines. From agitator fillers to tablet fillers, understanding the different types of machines available can help you make an informed decision when selecting your filling machinery.
Agitator Filling Machines are widely used for packages containing suspended or divided particles, such as granules or powder. This type of machine is designed to keep the particles suspended while accurately measuring and dispensing them into containers. Agitator machines are available in both ½ pint and pint capacities, ideal for smaller production batches.
Flow Filling Machines are designed for materials that flow freely, such as liquids and syrups. These machines meter a specific volume at each cycle, ensuring accuracy with each pour. Open-mouth baggers are also a type of flow filling machine often used for packaging bulk items such as flour or grain products into bags. They feature electronic devices that enable precise product measurement by volume in cases where exact weight measurements aren’t required.
Tablet Fillers are specialized equipment that fill tablets into containers at high speed with great precision and control over variables like temperature, viscosity, pressure and volume. Tablets can vary in shapes ranging from round capsules to irregular pieces making these machines highly versatile and ideal for complex product requirements. Electronic scanners can be used to ensure quality control by inspecting each filled container before it is closed off and labeled.
Sealing Equipment
It is a key feature of all food packaging machines, from vacuum packing machines to blister, pouch and skin packaging equipment. Sealing processes are used to hermetically seal packaging materials and protect the contents from contaminants such as moisture, light and oxygen. It also helps securely fasten the two main components that form the package – the material for bag forming and lidding material for sealing.
The sealing process depends greatly on the type of machine and package being constructed, but there is a wide range of common sealing options available in modern food packaging machinery designs:
Mechanical Sealers – These are typically used when operating with rigid packages such as trays or boxes, forming seals by pressing together 2 flat layers of material.
Heat Sealing – Used extensively in thermoforming and skin packing applications, heat sealers work by using hot air or electric heating elements to apply heat and pressure onto plastic films.
Ultrasonic Sealers – These utilize high-frequency vibrations to form robust seals without applying pressure or heat. They can prevent delamination due to changes in product temperature or humidity levels.
Vacuum Sealing – Mainly used for modified atmosphere applications, vacuum sealing removes air from a preformed seal in order to enhance product shelf life. This process also bonds two layers of plastic film together firmly during formation providing excellent tamper resistance qualities for food products after consumer purchase.
Labeling Equipment
Labeling equipment for packing and production lines is available in many variety of shapes and sizes. Proper selection plays a big role in the productivity, accuracy and efficiency of your production line. For example, if you’re planning to package flat items such as boxes or cartons, you need a flat class labeling machine that easily fits your size requirements. On the other hand, if you have round bottles or cans that require labels on the sides, you need a round bottle labeling machine or side of the class labeling machine respectively.
When selecting automated packaging machinery for your product labeling needs, consider factors such as the footprint it will take up on your shop floor or storage area, type of product to be labeled (flat materials like boxes/cartons/bags or cylindrical products like cans/bottles), availability of additional features like ‘built in’ embossing machines etc., as well as flexibility in terms of changing label settings without much trouble.
Moreover, proper evaluation accounts for any changeable items that may appear along the way. Ensure that your labeler is equipped to adjust itself to various portions and sizes using tools such as height gauge readings and optical sensors. Last but not least, study how the machinery can handle existing vacuums created by its own motors which could affect its performance and speed during operation times. Proper evaluation will ensure proper selection of machinery before making any purchase decisions helping increase efficiencies with minimized costs for repair/maintenance afterwards.
End of line Section and Equipment
The end of line section is the last portion of a packaging production process, where the package is closed and labeled. Different types of equipment may be required based on the type of product that you are packaging. Packaging machinery such as wrappers, tapers, and bundlers are used to provide uniformity in presentation of products to customers.
Case/Box Sealers – These machines use an adhesive or Heat activated tape to apply a seal on one or more flaps of boxes/cases. Case/box sealers can fold in various flap configurations including Straight Line, Random Lock and Right-Angle folds.
Sleeve Wrappers – These machines provide a durable sleeve for groups of products that are shipped in multiple quantity. Plastic Sleeves can be automatically applied over stacks of cartons with this machine.
Bundlers – Bundlers gather several individual packages together into a group and then they’re sealed with tape or strapping material. This reduces the labor cost per package since fewer operators are needed to process a given amount of product packages
Case/Erectors – This type of machinery is used to form cases around products before they’re sealed inside them with case/box sealers mentioned above. The empty cases will be folded in predetermined format then it will be put into position accordingly according to the product size prior to being filled with the products automatically with downstream equipment such as box forming machines or case packers
Box Forming Machines – Box forming machines are typically used alongside case erectors when different size boxes need either pre-molding into shape before it’s filled with product items by case packer or needs further manipulation after it’s formed by case erector such as tapering corners for better shipment protection
Case Packers – Case packers gathers specific product related items and seals them into already erected cases from upstream operations . For example, Snack Bars may need automating insertion onto trays, shrink wrapping etc before sealing them inside pre-formed trays at this stage
Palletizing Equipment- Each line end section mostly consists few layers palletizing equipment which normally also include end of line stretch wrapper, labeling station, Place centre etc which in turn assist proper pallet wrapping ensuring quick and safe transportation between locations
Popular Design Software used in designing Packaging Machines
Designing packaging machinery has become increasingly easier in recent years with the advent of design software used to create 3D solid models. The creation of a 3D model provides an interface to allow engineers and users to vet potential designs prior to committing resources and investment into tooling for producing a prototype. Popular software packages for designing equipment include Solidworks, Inventor and SolidEdge, which are typically integrated with AutoCAD to provide detailed 2D drawings in support of the project.
Solidworks is a 3D modeling program that is most used by mechanical engineers. It allows users to easily draw or modify parts and then mechanically assemble components into complete systems. It also allows users to simulate the product being designed, which is beneficial when considering design criteria such as force deflection or motion tracking over time. Inventor is an Autodesk program designed for creating accurate 3D models of systems. It comes with many simulations tools available for users regarding product performance after build completion, be it assembly performance or part sturdiness based on material choices during design construction.
SolidEdge from Siemens PLM is another popular modeling package used by machine manufacturers- allowing them to quickly sketch out parts before handing them off for creation within the machining environment – complete with models rendered in either wireframe or solid mode, providing complete transparency throughout the entire process from design inception through production milestone realization.
For any professional machine manufacturer looking to use a streamlined 3D flow-through process that’s both secure and compliant – these packages offer a huge range of functions ranging from Kinematic analysis & LDAR validation right through dynamic simulations such as vibration analysis; providing them with all they need within one single piece of software – ideal for crunching short deadline tasks on breakdown jobs & intricate terms alike!
Designing using CAD Software
Creating a successful packaging machine design can be a complex process. Using computer aided design (CAD) software can make the process easier by reducing the time and effort involved in creating each machine.
Designing using CAD software provides many advantages over hand drafting. The software offers an extensive library of stored purchased components, as well as ANSI, ISO, DIN, and JIS standard parts that are easily accessed and inserted into drawings. With CAD software, it is now possible to create a virtual prototype and then simulate how it will function when it is running in real life.
CAD programs offer tools such as top-down design capabilities to help engineers create all the necessary components of their machine designs more quickly and accurately. Weldment design tools allow for welding specific types of tubing in one step instead of several individual pieces that must then be welded together later on in production. Electrical designers have many advanced electrical layout capabilities, like interactive wiring diagrams for machines with multiple components or modules.
With CAD programs come built-in bill of materials (BOM) creation tools to allow engineers to track parts and components that go into the final machine designs easily and accurately to ensure reliable functioning during production runs or expansions over time. Finally, project documentation can quickly be produced so that all team members are working off of up-to-date drawings or vendor information when needed for manufacturing purposes or training down the road.
By leveraging modern CAD technology such as specialized engineering architectures like CATIA Systems Designers Cad platforms available today, teams working on complicated packaging machinery designs are able to reduce production costing while increasing safety standards in most manufacturing workspaces around the world
Packaging Automation
Successfully leveraging automation as a critical aspect of packaging depends on multiple design considerations. Automation requires technological development spanning package size and shape, package materials, machine portability and sanitation, product placement and speed, as well as machine programmability. By automating an industrial process, production output can be dramatically improved while integrating consistent quality control.
Packaging automation implies the use of programmable logic controllers (PLCs) which are configurable devices that control different actuators like robotics and pneumatics used in packaging machinery hardware components for product handling and insertion tasks. PLC’s provide reliable data management for packaging machines which may contain large amounts of data. Robotics systems are either stationary for design stability or mobile for increased capability using dexterous arms with motion-control capabilities.
Robotic arms feature a number of advantages such as better speed, higher accuracy and reliability than human beings when it comes to performing repetitive tasks such as packing products like chips or cookies into clamshell packages or containers along complex trajectory motions defined by the end user. It is possible to fully automate the entire packing process from mass infeed through product sorting into appropriate packages to final sealing or boxing at incredibly high speeds with almost zero downtime once setup correctly. Robots have various degrees of dexterity to handle various sized products in various shapes and forms such as bottles, cans, jars and cases that can be bundles up collectively in boxes or pallets by machines explicitly designed to do so while keeping stock levels topped up in automated warehouses or cells containing rows of shelving units stacked with assorted packages in constant supply mode with predetermined intelligence integrated through advanced algorithms designed specifically to keep your supply chain running smoothly at all times under any circumstance even under extreme environments using lightweight hydraulic structures executing incrementally faster speeds than humans ever could over years of natural degradation without fail.
Choosing Packaging Machinery
When selecting packaging machinery, many companies are faced with the issue of choosing between standard or off-the-shelf equipment or going with customized machinery. While on-the-shelf models will often provide a solution in the short term, they may not be the best option in the long-term. On the other hand, custom equipment comes with many benefits and may help a business better manage its operational needs. In order to ensure that you choose the best option for your business, here are some things to consider:
First, determine what type of automation needs you have; will you simply require basic packaging operations or do you need a more complex system? Understand that selecting standard equipment can meet lower-level needs but complex systems may require custom solutions tailored to specific operations.
Second, consider the cost of purchasing new versus getting refurbished machines. Refurbished machines are often more cost effective than buying new and could be suitable for businesses on a tighter budget. That said, refurbished machines should be thoroughly tested before adoption and if parts need to be replaced, they should take into account compatibility issues between older and newer parts.
Thirdly, think about whether or not it’s possible to modify existing off-the-shelf equipment using in house engineering capabilities. If little modifications would suffice as compared to investing in modified models or completely new custom pieces this could save time and money over time. Alternately if your company does not have available engineers then consider using qualified third parties capable of providing those services if needed.
Lastly, if working within restrictive budget constraints look at opting for partial automation such as manual parts inserters coupled with automated packing and stacking solutions which can offer an affordable compromise between full manual processes and fully automated solutions which may prove out of reach from financial standpoints in some instances.
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