In-depth Analysis Of Packing Machines: The Key To Improving Production Efficiency

The Basic Knowledge Of Packaging Machine Popularization

What is a packaging machine?

Simply put, a packaging machine is 1 kind of machine that can package products. It’s not just about putting things in a bag. Its main functions include: accurately “weighing” the product (measuring), “pouring” the product (filling), “sealing” the bag or box (sealing), and finally forming a complete “commodity package” (packaging). It can be said that without it, the production lines of many products cannot be turned at all.

Classification and working principle of packaging machine

There are many kinds of packaging machines that we come into contact with at ordinary times. If we divide them according to their functions, the common ones are: “filling machines” that fill bottles, “sealing machines” that seal bags, “wrapping machines” that wrap products with a layer of film, “strapping machines” that tie 1 piles of products together, and “labeling machines” that label products, etc.

According to the degree of automation, there are mainly “semi-automatic” and “fully automatic” in the market. Semi-automatic, usually requiring manual assistance, is suitable for situations where the output is small or the packaging form is changeable. Fully automatic is severe, from feeding to packaging, basically do not need manual intervention, efficiency bar!

According to the packaging form, there are more, such as the “particle packaging machine” that specializes in packaging particles, the “powder packaging machine” that handles powder, the “liquid packaging machine” that handles liquid, the “vacuum packaging machine” that pursues preservation, and the “shrink packaging machine” that makes the product more compact.

The working principles of these machines are actually ingenious. For example, granule packaging machines usually send granular materials into packaging bags by vibrating or spiral feeding. Liquid packaging machines may use piston type or flowmeter to accurately fill liquids. Vacuum packaging machines, as the name implies, pump out the air in the packaging bag and seal it to extend the shelf life of the product. Each machine has its own unique mechanism to adapt to different packaging needs.

The core components of the packaging machine

A packaging machine may look quite complicated, but when it is disassembled, it is mainly a few core parts.

• Transmission system: It is the power source for the operation of the packaging machine, just like the engine of a car. It usually includes motors, reducers, gears, belts, etc., to ensure that all components can work together.
• Control system: This is the “brain” of the packaging machine, and now most of them are controlled by PLC (programmable logic controller) or more advanced industrial computers. It is responsible for receiving instructions, processing data, and then issuing instructions to the actuator, such as controlling how much to measure, how long to seal, and so on.
• Actuator: You know from the name that this is the part responsible for “work”, such as cylinders, manipulators, heating rods, knives, etc., which complete specific packaging actions according to the instructions of the control system.
• Metering devices: This is critical, especially for products that need to be weighed accurately. It may be a load cell, volumetric measuring cup, screw gauge, etc., to ensure that the amount of product packaged each time is accurate.

Packaging Machine Buying Guide-How To Find The Best Solution For You

As a veteran who has been in the packaging industry for more than 20 years, I know how important it is to choose a packaging machine for the production efficiency and cost control of the enterprise. This is not only a technical work, but also an art.

Factors that must be considered before purchasing

Buy packaging machine, really can’t beat the head to decide. Every time I consult with clients, the first thing is to let them think clearly about these points:

• Packaging Material Characteristics: Are you packing solid, liquid, powder or granule? For example, powder materials have extremely high requirements for sealing, and liquids must consider filling accuracy and anti-drip.
• Packing form: bag, box or bottle? The different forms determine the type of equipment you need. You can’t expect a bagging machine to fill the bottles.
• Packing speed: How many products need to be packed per minute in your production line? This is a key indicator that directly affects the capacity of the equipment. The speed is too slow to increase production capacity. If the speed is too fast, the cost will soar again.
• Packaging accuracy: what is the allowable range of error? Some products, such as drugs, require millimeter-level accuracy, which is almost impossible.
• Automation level: automatic, semi-automatic or manual? It depends on your labor cost and production scale. Of course, most enterprises are now inclined to high automation, after all, can save a lot of things.
• Budget: Money is always a topic that cannot be avoided. Only by defining your budget can you choose within the right range.

Comparison of common packaging machine models and their applicable scenarios

I found that many people are not very clear about the model of the packaging machine, which is easy to confuse. In fact, each packaging machine has its “specialty”.

Take the granule packaging machine, it is mainly used to pack those granular materials with good fluidity, such as seeds, nuts, washing powder particles, etc. Its advantage lies in accurate measurement and fast speed. Liquid filling machine is more diverse, there are normal pressure filling, negative pressure filling, pressure filling and so on, such as beverages, edible oil, cosmetics, these liquid products are inseparable from it.

In order to make everyone understand more intuitively, I have compiled a table to compare the characteristics of different types of packaging machines:

Type of packaging machine	Features	Advantages	Disadvantages	Applicable industry
granule packing machine	Accurate measurement, high-speed packaging	High efficiency and wide applicability	Not suitable for powder and liquid	Food, medicine, chemical industry, agricultural products
powder packing machine	Dust-proof design, screw metering	High precision, reduce loss	Easy to block, cleaning and maintenance is more troublesome	Food, medicine, chemicals, building materials
liquid filling machine	Precision filling, anti drip	High degree of automation, hygiene	Many kinds, complex selection	Beverage, edible oil, cosmetics, medicine, daily chemical
vacuum packaging machine	Vacuum, extend shelf life	Good preservation effect, save space	Relatively slow	Food, meat products, electronic products
Box sealing machine	Automatic sealing box, improve efficiency	Save manpower, standardize	Single function, need to cooperate with other equipment	Logistics, e-commerce, food, daily chemical
Winding packaging machine	Membrane winding fixed to prevent scattering	Protect products and improve transportation safety	Cost of consumables, large equipment area	Logistics, warehousing, building materials, electronic products

Key indicators to evaluate the performance of packaging machines

Whether a packaging machine is good or not depends on the price. I’m more interested in the “inside” of it “.

• Production efficiency: Needless to say, this is directly related to your output.
• Failure rate: the machine is always out of order, no matter how cheap it is, it is useless to stop the machine.
• Energy consumption: don’t underestimate this, long-term operation, electricity is also a big expense.
• Operation convenience: the best fool operation, can reduce training costs, but also reduce the risk of misoperation.
• Maintenance costs: Are spare parts expensive? convenient maintenance is not convenient? All this has to be included.

Procurement Process and Precautions of Packaging Machine

My experience tells me that the process of purchasing packaging machines must be standardized and the details must not be spared.

1. Requirements analysis: This is the first and most important step. You have to be clear about what you need.
2. Market Research: Don’t rush to place an order, look at different brands and understand the market situation.
3. Inquiry: 3 goods do not suffer losses, but don’t just look at price, performance and service are more important.
4. Field investigation: If conditions permit, it is best to go to the manufacturer to have a look on the spot, and even bring your own materials for a test. Seeing is believing, it’s better than anything.
5. Contract signing: must see the details of the terms, especially after-sales service and warranty period.
6. After-sales service: There will definitely be problems when the machine is used for a long time. A good after-sales team can save you a lot of worry.

Budget and Cost-Benefit Analysis

Finally, let’s talk about money. When buying a packaging machine, you can’t just stare at the immediate purchase cost.

• Purchase cost: The selling price of the device itself.
• Operating costs: electricity, water, consumables (such as packaging film), maintenance costs, labor costs, etc.
• Long-term benefits: How much can this machine help you improve your efficiency? How much labor reduction? How much loss reduction? These are invisible gains.

A seemingly cheap machine with high failure rate and high energy consumption may be more expensive in the long run. However, if a device with a larger initial investment is efficient, stable and durable, it can save you more in a few years. I have seen too many enterprises in order to save a little money, finally suffered a big loss. Therefore, it is wise to consider comprehensively and do a comprehensive cost-benefit analysis.

Packaging Machine Operation And Maintenance-Ensuring Efficient Operation

Daily operation process and safety specification

To tell the truth, in our business, the thing before the packaging machine was turned on was really not a formality. I usually walk 1 circles around the equipment first. Whether the power supply and air supply are connected properly and whether the emergency stop button is easy to use are all cliches. In particular, the material warehouse must be confirmed that there are enough products in it, otherwise it will not be found until the machine is started. isn’t that a waste of time?

When operating, in fact, the key points are: the parameters are set accurately, the feeding system should be smooth, and the sealing quality. I usually use several batches of products to test run first to see if the seal is firm and the incision is neat. Sometimes, the effect can be much better if the parameters are fine-tuned. As for shutdown, it is even simpler. Turn off the heating first, then turn off the feeding, and finally the total power supply. This is not to save electricity, but to protect the equipment and extend its life.

Common troubleshooting and maintenance

We all know that machines cannot never go wrong. The one that impressed me most was that there were batches of products. The seal was always empty and the tone was wrong. Later, it was discovered that it was caused by a small stain on the sealing heating rod and uneven heat conduction. Therefore, in case of problems, don’t rush to dismantle the machine. Sometimes small details are the key.

The common problems are nothing more than lax sealing, inaccurate measurement and material blocking. Sealing is not tight, in addition to the heating problem, may be the pressure is not enough or sealing film itself has a problem. If the measurement is not accurate, it depends on the calibration of the sensor or whether there is foreign matter in the weighing bucket. Card material is usually a problem with the feeding mechanism or the product size is not standard.

Therefore, daily maintenance is particularly important. Regular cleaning is a must. Keeping the equipment clean can effectively reduce many minor problems. Lubricate those transmission parts so that the machine runs smoothly. There are also screws, which may loosen after a long time. It is necessary to tighten them regularly. Vulnerable parts, such as blades and heating tapes, must be prepared, checked in advance, and replaced as soon as their life is approaching. Don’t wait until they are broken before your hands and feet are busy.

Improve packaging efficiency and optimize production lines

What we pursue is not to maximize efficiency. In order to improve the efficiency of the packaging machine, in addition to the daily maintenance in place, it will have to “toss and turn”. For example, for different products, I will find out the best combination of parameters, so that when the production can be quickly adjusted in place. If the equipment allows, upgrading some key components, such as a faster feeding system or a more accurate temperature control module, the effect is immediate.

Of course, now pay attention to intelligent. Intelligent packaging system, I think this is a big trend. It can automatically monitor equipment status, predict failures, and even automatically adjust parameters according to production plans. Integrating the packaging machine with the entire production line to achieve data sharing and automatic control is really worry-free and efficient. Recently, I have been considering whether we can also introduce such a system to raise the production efficiency to a higher level.

The Application Of Packaging Machine In Various Industries And Innovation

Food industry: automated packaging solutions for snacks, beverages and seasonings

When it comes to food packaging, it is really the “main battlefield” of our packaging machinery “. Do you think, every day in the supermarket of those dazzling array of snacks, drinks, seasonings, which is not processed by packaging machinery? Take snacks as an example, from potato chips to biscuits, from bags to boxes, high-speed vertical packaging machinery and bag packaging machinery are the most common. They must not only ensure fast packaging, but also ensure accurate measurement and product integrity.

I remember one time we were working on a project for a large snack manufacturer. Their production line required to pack hundreds of packages of products per minute, and they had to switch quickly according to different tastes and specifications. It was impossible to achieve without an efficient automatic packaging scheme.

Pharmaceutical industry: precise aseptic packaging of tablets, capsules and liquid drugs

Packaging in the pharmaceutical industry is even more demanding and can be described as “harsh. After all, this is related to people’s health and life safety. Tablets, capsules, liquid drugs, each 1 has its own special packaging needs. For example, blister packaging machinery is widely used in tablet and capsule packaging, which can ensure the independent sealing of each drug and prevent cross contamination.

For liquid drugs, such as injections, filling and sealing must be carried out in a sterile environment, and there are extremely high requirements for the material, cleanliness and accuracy of the equipment. In our programs, online testing systems are often added to ensure the integrity and eligibility of each 1 box of drugs, which is not sloppy at all.

Daily chemical industry: filling and sealing of washing products and cosmetics

Daily chemical products, such as shampoo, shower gel, laundry detergent and cosmetics, are characterized by many varieties of packaging, different container shapes, and many products have high requirements on appearance. Liquid filling machinery, capping machinery, labeling machinery is the most commonly used equipment in this industry.

Especially cosmetics, all kinds of strange shaped bottles, glass, plastic, filling accuracy and sealing quality directly affect the brand image. Moreover, the production volume of daily chemical products is large, and the production line must be highly automated to cope with the rapid changes in the market.

Other industries: electronic products, hardware, etc

Do you think packaging machinery only serves daily consumer goods? That would be wrong. In the electronic products, hardware these industries, packaging machinery also plays an important role.

For example, small parts in electronic products can be packed quickly and accurately with automatic counting and packaging machinery. Hardware screws, nuts and bulk packaging mechanical energy greatly improve efficiency. Although they are not as eye-catching as the food and pharmaceutical industries, they are equally important for improving the production efficiency and reducing labor costs in these industries.

Intelligent Packaging and Industrial Upgrading

To say the future trend, it must be intelligent packaging and intelligent upgrading of the industry. Now, packaging machinery is no longer a simple physical operation equipment, it is becoming more and more “smart”.

• Equipment interconnection: Through sensors and networks, packaging machinery can monitor the operating status in real time, collect production data, and realize the interconnection and communication between equipment. The scheme we are designing now will upload the equipment data to the cloud, so that customers can grasp the production situation anytime and anywhere.
• Data analysis: The massive data collected can help companies optimize production processes, predict possible equipment failures, and even guide the development of new products. This is like packaging machinery with a “brain” that can continuously learn and optimize.
• Artificial intelligence: Artificial intelligence can play a role in visual inspection, fault diagnosis, and even product packaging optimization. For example, the artificial intelligence vision system can detect packaging defects more accurately, which is much more efficient than manual.

It can be said that the intelligent packaging machinery under the background of industrial intelligent upgrading is not only a link in the production line, but also a data processing center and a decision support system.

This is no longer a simple machine to replace labor, but the collaborative work of machines and intelligent systems, which brings a qualitative leap in production efficiency. We veterans in the industry are also constantly learning new knowledge and following the pace of the times. The charm of this industry lies in its development and innovation.