Key Questions to Ask When Ordering Automatic Packaging Line

Automatic shrink wrap machines are a step up from manual or semi-auto machines. Companies using automatic machines are often packaging thousands of products daily. The initial costs are substantially more than lower volume machines. Though the capital expenditures may be higher, the efficiency will quickly pay for itself. There are always many questions when purchasing an expensive piece of machinery. Many people desire to see the machines in person or at least have products run on the machine before purchasing. We agree with that and offer in-house testing and viewing before making a purchase. Unless familiar products are being packaged, we require testing before selling a machine.

XuTengDa are exported all over the world and different industries with quality first. Our belief is to provide our customers with more and better high value-added products. Let's create a better future together.

Below are common questions asked by companies interested in an automatic shrink wrap machine.

1. What is the cost? 

The cost of a fully automatic machine with accessories will be substantially more than smaller shrink wrapping machines. Many automatic machines with the right equipment can cost more than 100k. One-piece automatic machines for 30-40K will package smaller items. Like anything, you can shop and find some automatic machines for much less but question the quality and longevity of the device.

2. What size of products can the machine accommodate?

Large or small, the product size matters. There are multiple styles of auto machines; knowing the largest and smallest product being run will help determine what size and style of machine will be needed. The weight of the wrapped product is an important question to determine the proper film required in the machine.

3. Can I run samples on the machine?

Samples are strongly encouraged when purchasing an automatic shrink wrapper. Unless the machine supplier is familiar with packaging your style of products, testing should be conducted. The testing will show which machine is suitable, what shrink film is best, and if heat shrink wrapping is the right solution for the product being wrapped.

4. What additional machines or conveyors are needed?

Many auto sealers are the sealer only, a shrink tunnel will be needed to heat the film and form the material around the product. Be sure to consider a tunnel that will keep up with the speed of the sealer and fit the products being wrapped.

A powered infeed conveyor is standard for most automatic setups. The powered infeed conveyor allows the products to be placed in the production line. Conveyors come available with many different belts and options.

5. What are the electrical supply requirements?

One-piece auto machines may have one power cord versus a two-piece device that will have two lines with different power requirements. Most machines will come bare wire for hard wiring or installing a plug that matches the power supply.

It is crucial to have the correct power supply at the machine. Running long power cords will drop the electrical output at the device and cause problems. We recommend having a licensed professional install electrical plugs and properly check for the correct electrical supply to the machine.  

6. How many products can the machine run per minute?

Automatic shrink wrap machines can vary in the number of products per minute. More oversized products that are longer will generally take more time to move in and out of the sealing area. Smaller products can quickly move through the machine and can be run at faster speeds.

On the low end, an automatic shrink wrap machine should be able to package at least 17-20 products per minute. Other machines are capable of higher production numbers. Some machines packaging smaller products can wrap 60-80 products per minute. The average expected speed would be between 25-40 products per minute with a fully automatic heat shrink wrapper.

7. How complicated is the machine setup?

We do not recommend ordering a fully automatic packaging line without a technician setting it up and conducting training. Adjusting the machine for each product with conveyor belts and film threading would be better for someone skilled to show how to set up the equipment properly. Once set up and training is completed, employees should know how to adjust the machine for each product and reload film as needed. We strongly urge companies not to order expensive equipment based on price with no support or technical assistance. 

8. How much time does it take to adjust the machine?

Product adjustments are necessary if several sizes of products are being run. If only running one product size, skip this question and move to number 8. Some machines have manual product adjustments, consisting of crank handles to adjust the machine to fit the wrapped product. Other digital devices have product memories and automatic product adjustment to adjust the machine as needed to fit the product being wrapped.

The automatic product adjustment feature is perfect for companies wrapping dozens of different products. Each product can have a saved setting for workers to enter the right adjustment for each product. Without an auto adjustment, the sealing head, film head, conveyors, and film unwinds will need to be changed between products with significant size differences.

9. What material is recommended for use with the machine?

What type of automatic shrink wrap machine are you looking for? Different shrink materials will be needed to wrap small products, large products, heavy products, or bottles. Find out what material the shrink wrap machine uses and ensure it is readily available. Many companies get into binds when purchasing packaging machines from not knowing if the material is available from more than one source.

10. Can parts and services be found?

This should go without saying if spending tens of thousands of dollars on an automatic shrink wrapper. The availability of parts should be one of the first questions to consider. With an automated machine’s production, downtime can cost more than the part needed and eventually the device itself. Be sure replacement parts are available.

In addition to parts, look into the service available. There may be issues that come up demanding a trained technician. If that is not available, what will you do? Hire a third-party company to attempt to fix the machine? If possible, on the front end, inquire about parts and servicing for any automated packaging equipment you are planning on buying. 

11. Do your products need a closing gap conveyor?

Automatic sealers will have a conveyor belt transporting products into and out of the sealer. Between the two conveyors is where the sealing bar can be found. Products with small dimensions can fall into the gap.

Closing gap conveyors are used to eliminate lost products. The closing gap allows the two conveyors to come together, momentarily closing the gap between the conveyors. It is essential when packaging small products such as cosmetics and baked goods.

12. What are payment and financing options?

You know a general idea of cost, now how to pay for it. What financing or payment options are available with the machine? Some companies require a deposit, and the remaining balance due once the machine ships. Other companies offer lease options. Users pay a monthly rate, and scheduled maintenance is also provided with some lease contracts. Find an option that fits your needs and a machine that accommodates the products and estimated production levels.

The company is the world’s best Automatic Packaging Line supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.

Related links:
Laser Welding Machine for Lithium-ion Batteries 2023 - dplaser
The Best Places to Buy Subrack Chassis Online and In-Store
Why Roller Mills Are Superior to Stone Mills in Modern Milling

13. Can the machine be synced with an existing line?

To purchase automated equipment for end-of-the-line packaging, you should consider if the device will sync with the existing line. Does it have the right drive and program to do so? If not, can the speed be matched manually to sync with an existing line?

14. How does the machine ship?

Most automated packaging machines are not small or cheap. Some are custom and one-of-a-kind. If they become damaged in shipping, it may be months before the machine can be replaced. Determine if the machine is shipped on a dedicated load or if it will be interlined between multiple freight carriers.

In addition to the freight carrier transporting the equipment, how is it all crated and packaged? You will need a loading dock or forklift to unload the machine, but will forklift extensions be required? Will any tools be needed to uncrate or unpackage the device? These are essential questions to consider when the machine is ready to ship.

15. Where does the machine ship from?

Will the machine be shipping internationally direct to your facility? That can have delays at the port and possible damages or missing items upon arrival. If the machine is shipping domestically, will it be delivered via freight carrier or locally? Check the location and lead time to avoid disappointment and possible production loss.

16. How long will it take to receive the machine from the order date?

Most automatic shrink wrap machines are not stock items. There are times a stock option is available, but it does not happen often. If there is a lead time on the machine, find out how long the lead time is and when it would be expected in stock. Ensure you are dealing with a reputable company that accurately quotes lead times and keeps promises.

Conclusion

The difference in efficiency and output of an automatic shrink wrap machine compared to a manual or semi-auto machine is a game-changer. Many questions should be addressed along with logistics and setup issues, but a suitable machine is well worth it. Take the time to ensure you are working with the right company to fit your needs when purchasing your next automated shrink wrapper.

When starting a packaging project, many questions arise about the configuration of the line, the adaptability to the production itself, connectivity and communications, etc. An end-of-line project, and in particular pallet packaging, has a great technical complexity with many particularities and elements to be agreed upon by the engineering departments of the manufacturer and the customer.

Without going into too much detail and technicalities, in this article, we have compiled the most Frequently Asked Questions (FAQ) that arise when approaching a new packaging project and their respective answers from our experience in a multitude of end-of-line projects.

Note: We define a packaging line as the end of the line after palletizing the product in its primary or secondary packaging. It is therefore the tertiary packaging line or pallet packaging, ready for storage and shipment.

The Top 10 FAQ of the Packaging Line

1. What are the essential systems in a packaging line?
2. How is the integration of the packaging line carried out?
3. How many systems can be included in a packaging line?
4. Can automatic and semi-automatic systems coexist on the line?
5. Can the in-house conveyor line be used with new packaging systems?
6. What are the standard dimensions of a Stretch Hood packaging line? How much space does it take up?
7. Which pallet formats can the Packaging line handle?
8. What type of vehicles and pallet transport are used in a packaging line?
9. Which automation systems can a packaging line be connected to?
10. Is the packaging line also part of Industry 4.0?

1. What are the essential systems in a packaging line?

A packaging line is composed of systems to protect and hold the product for transport and storage. It always includes at least one system that provides protection and support, such as the Stretch Hood or the Automatic Stretch Wrapper) If necessary, depending on the type of product and characteristics of the project, it also includes other fastening systems such as pallet strapping systems, wrapping machines for support, sealing system, etc.

2. How is the integration of the packaging line carried out?

In each project, it is necessary to study in detail the integration with the customer’s existing palletizing and production line. The engineering team evaluates, studies, and designs the line elements that best fit the customer’s needs, looking for an optimal connection and smooth flow.

Integration aspects of being taken into account for the integration with the end of the line:

• Location: facility space and dimensions, environment, and temperatures.
• Safety perimeters: safety fencing and signaling.
• Pallet infeed and outfeed flow: conveyor and lifting systems.
• Pallet transport vehicle movement flows.
• Connectivity and communication: with production line, logistics warehouse, etc.
• Production specifications: pallet formats, infeed and outfeed flows
• Connection and intervention of other systems: labeling, weighing, etc.

3. How many systems can be included in a packaging line?

It is possible to integrate, a priori, all packaging systems that the customer demands or that the project requires. The limit is the facility space. Once again, the Technical Engineering department looks for the best combination of the necessary systems, prioritizing the final packaging objectives and space optimization. Even if the customer requests more systems, each project is studied to see their need according to the fundamental objectives.

For example:

• To respond to a high production rate, it is recommended to have double packaging systems or systems with high-speed accessories. For instance, a high production line may require a double strapping system and a high-speed Stretch Hood wrapping system.

• To adapt to the available floor space, a conveyor line is designed to transfer the pallets between the different packaging systems in the smallest possible space. For this purpose, additional conveyors are used, such as rotating conveyors, elevators, 90º transfer conveyors, etc.

• To meet the requirements of fastening the load, sometimes the customer requires more strapping or wrapping systems, but the engineering department can dismiss the need or recommend the use of a system as a substitute for another, as happens with the automatic wrapping machine that sometimes replaces the strapping.

4. Can automatic and semi-automatic systems coexist on the line?

In principle, the automatic packaging line is designed to fully automate the end of the line, but there are occasions when the customer’s facility or production can continue to use semi-automatic systems.

When defining a line project, a pallet flow is designed in which everything from the input to the output after the final stretch hooding is automatic. To guarantee productivity, it is not recommended to “stop” this process to include a semi-automatic system in the middle of the line. But there may be some exceptions where there are manual or semi-automatic systems before or after the packaging line, the most common being pallet transport vehicles.

Some examples of the co-existence of automatic and semi-automatic systems:

• Semi-automatic pallet entry into the line, either by pallet truck or forklift. In this case, there is a semi-automatic element, since the operator must input the pallet data to be packed on the control panel. When the entry is made by AGV, the same vehicle communicates the format to the PLC of the line automatically.
• Sealing, manual strapping, or stringing after palletizing and before the packaging line: when minimum stability of the pallet is required for the transport of the pallet to the line, manual or semi-automatic systems are used to perform this pre-packing.
• The output of the pallet by forklift or pallet truck is similar to the indeed entry of the pallet.
• Pallet weighing or labeling system excluded from the packaging line. In this case, the transport to this station should be semi-automatic.

5. Can the in-house conveyor line be used with new packaging systems?

Whenever required by the client, we try to ensure that the new packaging line is as compatible as possible with the existing conveying systems. If this is a renovation of the installation and the existing conveyor line is in good condition and meets the requirements to adapt to the new systems, it could be used. Another type of adaptation would be to connect the line to the existing conveying system through connection and elevation systems.

6. What are the standard dimensions of a Stretch Hood packaging line? How much space does it take up?

If we are referring to Innova’s Stretch Hood system only, the line can be located in installations with a smaller footprint than usual. In addition to the fact that the Stretch Hood machine is designed to occupy as little space as possible, the conveyor line can be adapted as much as possible to the customer’s facilities, using the connection, rotation, and elevation systems, as mentioned in previous questions.

7. Which pallet formats can the Packaging line handle?

Although this is one of the most frequently asked questions, the answer differs greatly from case to case. At Innova, our standard packaging line with Stretch Hood is designed for the most standard pallets in several sectors such as construction, ceramics, chemical, agrifood, etc. We work with minimum pallet measures of 32 x 24 inches (800 x 600 mm), a maximum of 80 x 55 inches ( x mm), and heights up to 100 inches (2.500 mm). If you have a different size or very different pallets, please contact us without commitment and we will study the feasibility of your project according to the packaging systems that your production needs.

8. What type of vehicles and pallet transport are used in a packaging line?

In a total end-of-line automation project, it is common to include AGVs / LGVs (Automatic Guided Vehicles) used to transport pallets from the palletizing line to the packaging line and from there to the logistics warehouse. Even so, it is very common for this type of vehicle to coexist with semi-automatic vehicles, such as forklifts with drivers or motorized pallet trucks.

Innova’s packaging line is prepared for access by all types of transport vehicles, using ground-level transport systems for pallet trucks or roller conveyors adapted to AGV infeed.

9. Which automation systems can a packaging line be connected to?

In a packaging line project, it is essential that the packaging line communicates and agrees with the existing system. In the case of Innova’s line, we connect with the most common PLC systems. We offer integrations and compatibility with PLC systems such as Omron, Siemens, Rockwell, or Schneider.

Check without commitment the compatibility with the system of your factory.

10. Is the packaging line also part of Industry 4.0?

Yes, packaging, like any factory production process, is an element of Industry 4.0. Packaging automation is an essential step towards Industry 4.0 since most of the packaging systems are already interconnected with the production system and ERP of the company.

In the case of Innova’s packaging line, we have intelligent components that offer performance reporting, remote connection to the line, fault diagnosis, and predictive maintenance of wear and possible repairs.

In short, all questions must be clarified at the time of the definition and design of the packaging line project. At Innova, our Engineering and Technical-Commercial Consulting teams study every detail and requirement to achieve optimal, efficient, and high-quality packaging.

If you are looking for more details, kindly visit Industrial Robot Packaging Machine.