Production and packaging automation solutions

In manufacturing, packaging is often the final stage before storage or shipment, so its efficiency can directly affect the entire production flow. When packaging is too slow, even an efficient production line can start to bottleneck.
Properly selected packaging equipment helps reduce manual handling, standardise results, control material consumption and increase overall process efficiency.
8boxes.lt offers packaging equipment for manufacturing companies – from strapping machines, carton sealing equipment and bag sealing equipment to vacuum packaging, pallet wrappers and labelling solutions.

When is it worth automating the packaging process?

Packaging automation does not necessarily mean a fully robotic production line.
In most cases, it is practical to start with the process that:

• takes the most employee time;
• is repeated many times per shift;
• requires many identical manual actions;
• is difficult to standardise;
• becomes a bottleneck in the production flow;
• consumes a large amount of packaging materials;
• creates significant physical workload.
  Even automating a single packaging stage can noticeably improve the efficiency of the overall process.

Carton sealing automation

When products are regularly packed into cardboard boxes, manual sealing can become time-consuming.
Carton sealing equipment can help to:

• speed up box preparation;
• achieve more consistent sealing;
• standardise tape consumption;
• reduce the number of manual actions;
• make the operator’s work easier.
  The greatest benefit is usually achieved when similar-sized cartons are packed regularly.

PP strapping automation

PP strapping is commonly used to secure cardboard boxes and lighter loads.
For lower volumes, manual strapping may be sufficient, but as volumes increase, businesses can move to:

• semi-automatic PP strapping machines;
• automatic PP strapping machines;
• solutions integrated into production lines.
  Strapping machines can help standardise strap tension and reduce the number of actions required from the operator.

PP/PET strapping for heavier loads

Heavier loads and pallets often require stronger securing.
In these cases, PET strapping can be used together with a manual or battery-powered tool.
A battery-powered PP/PET strapping tool can:

• tension the strap automatically;
• weld the strap ends;
• help achieve more consistent results;
• reduce physical workload;
• speed up repetitive strapping tasks.

Bag sealing automation

Manufacturing operations often package small products, components, food items or other goods into plastic bags.
Bag sealing equipment can help standardise the sealing process and achieve a more consistent seal.
When choosing equipment, consider:

• bag material;
• sealing width;
• package size;
• workload;
• required throughput.

Vacuum packaging

When a product requires airtight packaging and air removal, vacuum packaging equipment may be suitable.
It can be relevant for:

• food manufacturing;
• component protection;
• small products;
• products that need to be packed more compactly;
• processes where a more consistent vacuum result is required.
  The right machine should be selected according to product size, package type, required vacuum level and workload.

Shrink packaging solutions

Shrink packaging is used when a product or group of products is enclosed in heat-shrink film.
These solutions can be useful for:

• bundling multiple units;
• product protection;
• transport packaging;
• retail packaging;
• standardised grouping of products.
  When choosing shrink equipment, consider product dimensions, film type, required throughput and heat source.

Pallet wrapping automation

When finished products are loaded onto pallets, manual stretch wrapping can become slow and inconsistent.
Pallet wrappers can help to:

• standardise wrapping cycles;
• control film tension more accurately;
• reduce physical workload;
• achieve more consistent results;
• use machine stretch film more efficiently.
  If stretch film consumption is high, models with a prestretch system are worth considering.

Label printing and marking

In manufacturing, labelling is important for both product identification and warehouse or logistics processes.
Label printers can be used for:

• product labels;
• barcodes;
• batch numbers;
• production dates;
• warehouse locations;
• shipment labelling.
  Automated or well-standardised labelling helps reduce manual actions and the risk of errors.

Packaging automation in stages

There is no need to automate everything at once.
A practical path may look like this:
Stage 1 – optimise the workstation and tools
Improve material layout and use suitable dispensers, holders and hand tools.
Stage 2 – automate individual processes
Automate carton sealing, strapping, bag sealing or pallet wrapping.
Stage 3 – integrate processes
Connect separate machines into a more consistent production and packaging flow.
Stage 4 – move to higher-level automation
When throughput justifies it, consider conveyor systems, automated product feeding, robotic palletising or other individually designed solutions.
A staged approach makes it easier to invest first in the areas where automation provides the greatest practical benefit.

When does robotics make sense?

Robotics is generally a higher level of automation and is not necessary for every manufacturing company.
It may be worth considering when:

• production flow is high and stable;
• processes are well standardised;
• the same operations are repeated continuously;
• higher throughput is required;
• repetitive physical work is difficult to staff;
• automating individual processes is no longer sufficient.
  Robotic solutions may include product feeding, carton handling, palletising, transport between workstations or integration with packaging equipment.
  These are usually individually engineered systems and should not be treated as standard off-the-shelf packaging equipment.

How to calculate the benefit of automation

When evaluating equipment, do not look only at the purchase price.
A useful comparison is:
Current labour cost + packaging materials + downtime + errors + rejects
versus:
Equipment investment + operating cost + remaining operator time + material consumption
A simple payback estimate can be calculated as:
Equipment investment ÷ monthly savings = approximate payback period
It is also worth including additional benefits such as:

• higher throughput;
• more consistent quality;
• lower physical workload;
• ability to increase production without increasing headcount at the same rate.

How to choose which process to automate first

Start by observing the current packaging process.
Evaluate:

1. How long each packaging stage takes.
2. Where employees perform the most repetitive actions.
3. Where unfinished products accumulate.
4. Where the most packaging material is used.
5. Which stage depends most heavily on the operator.
6. Where physical workload is highest.
7. Which process limits overall production capacity the most.
   The first process to automate should not be the most impressive one, but the one that creates the greatest real loss or constrains throughput.

Packaging automation from product to pallet

Depending on the manufacturing process, the packaging flow may look like this:
Product → bag / primary packaging → sealing or vacuum packaging → labelling → cardboard box → carton sealing → PP/PET strapping → pallet → stretch film → warehouse / transport
Not every company needs every stage.
The key is to make sure individual solutions are compatible with each other and match the actual production flow.
At 8boxes.lt, you can find packaging equipment, packaging materials and solutions for different manufacturing and packaging processes.

Need help automating your packaging process?

If you want to automate a manufacturing packaging process, contact 8boxes.lt.
To assess the right solution more accurately, it is useful to provide:

• the type of product being packed;
• package dimensions;
• the current packaging process;
• the number of units or cartons per hour or shift;
• the packaging materials currently used;
• the process stage that currently takes the most time.