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The Packaging Line

The document discusses packaging lines, which take products from production lines and package them efficiently using multiple coordinated machines. A packaging line receives products and materials and uses machines like fillers, cappers, labelers, and packagers to form complete packaged goods. Proper operation requires balancing machine speeds and timing, and considering how product, material, and machine characteristics impact the line's performance.

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Rami Abdelaal
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232 views26 pages

The Packaging Line

The document discusses packaging lines, which take products from production lines and package them efficiently using multiple coordinated machines. A packaging line receives products and materials and uses machines like fillers, cappers, labelers, and packagers to form complete packaged goods. Proper operation requires balancing machine speeds and timing, and considering how product, material, and machine characteristics impact the line's performance.

Uploaded by

Rami Abdelaal
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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The Packaging Line

Introduction
Through the years, packages have developed from large
leaves, and other containers found in nature into a group of
mass-produced containers that are frequently formed from
synthetic materials, such as barrels, boxes, jugs, bags, or
wrapping paper.
Introduction
The modern package serves a number of different
functions:
l  to contain the product
l  to protect the product.
l  to attract attention
l  to facilitate display
l  to provide convenient dispensers
Introduction
The development of packaging machinery has made it
possible to efficiently produce packaged goods in large
quantities and a wide variety of forms.

l  The many operations involved in the preparation of a


package are performed by a number of different
machines in a packaging line. These operations include:
l  measuring and filling the product
l  closing or sealing the container
l  applying a label
l  check-weighing
l  inspecting
l  preparing the individual packages for shipment
The Packaging Line
What is it?
l  The packaging line consists of a group of packaging
machines with controls that make them work together
as one.

l  Although the separate machines may have been


designed and built by different companies, they are
linked together and controlled as a synchronized unit.

l  Packaging lines are made up of groups of packaging


machines in much the same way that the machines
are constructed from components.
The Packaging Line
What can it do?
Converting the product it receives from the production line
into individual and grouped packages.

The packaging line receives the product, containers, lids,


adhesives, labels, wrapping material, and other materials
that are needed for the package. The machines use these
materials to form, fill, seal, and deliver a complete package.

These packages provide protection for the products,


identification of the contents, decoration, advertising,
instructions, and a means for distribution.
The Packaging Line
What can it do?
In many plants, the packaging line is physically attached to
the production line so that product is fed directly into the
packaging line by a conveyor system.

In these systems, the production and packaging lines


operate as an integrated system. However, the production
and packaging lines are frequently separated.
The Packaging Line
[Example] a bottled water procedure:
1)  The bottles are fed into its packaging line through a
uncasing machine
2)  The bottles are cleaned
3)  The liquid filler measures the water and fills the bottle
4)  The bottle is capped
5)  The filled bottle is inspected
6)  The bottled water is sterilized
7)  A label is applied
continued
The Packaging Line
8)  The bottled water is inserted into a box
9)  The box is closed
10)  Product codes and dates are applied
11)  The boxes are gathered
12)  The boxes are marked, sealed, and loaded onto
pallets for shipment

This entire operation takes place on a packaging line


which contains 10 or more different machines
operating together.
Line Organization
Line and Packaging Machines
l  Many packaging lines contain a group of automated
packaging machines that operate at high speeds. A
problem in one machine can affect the operation of all
the other machines in the line.

l  The individual packaging machines are connected by


conveyors or other product feed devices and are
adjusted, timed, and controlled so that they work
together.
Line Organization
Line and Packaging Quality
l  The operation of a packaging line and the quality of the
package it produces is dependent upon the interaction
of:
l  the product

l  the containers or packaging material

l  the machine capabilities

l  the operator’s skill

l  the machine maintenance


Packaging Materials
The product’s physical characteristics can make it easy or
difficult to package:
l  A product that tends to lump or become sticky as the
result of changes in the humidity or production process
can be difficult to fill and require special check-weighing
or monitoring equipment
l  Fragile products may require special handling to prevent
breakage
l  Carbonated beverages require a sealed filler that does
not allow the CO2 to escape
l  Corrosive or hazardous products may require special
measures to protect the operators and packaging
machinery
Packaging Materials
Machinability is the ease with which a product, packaging
material, or container moves through the line and produces
a good quality package;
l  Containers that are difficult to hold in position and heat-
seal materials that melt onto the machine are
considered to have poor machinability

l  A film web with one type of coating may move through
the machine with no difficulty. The same film with a
different coating may bunch up, wrinkle, tear, or cause
other types of problems
continued
Packaging Materials
l  A folding carton that absorbs moisture from the
atmosphere or has irregular flaps can cause the
machine to jam or tear the carton

l  An adhesive containing too much solvent may require


additional drying time

l  A lightweight bottle that topples over will stop or jam


the machine
Machine Capabilities
Speed
Each packaging machine is designed to operate most
effectively within a particular speed range, with particular
types of products, and under given sets of conditions.

l  A packaging line cannot be expected to produce an


operating speed or deliver a quality of package that
exceeds the capability of any of the machines in the line

l  The limitations of the line are determined by the


slowest or least-accurate machine in the line
Line Balancing
l  The line must be balanced and timed so that machines
will operate as one integrated unit;

l  Timing the line sets all the machines to run at the
same or compatible speeds, and it starts and stops
each operation at the proper time;

l  When one machine is running too fast, excess product


backs up down the line. When a machine is too slow,
the line backs up, and machines down the line do not
receive enough product;
Line Balancing
How to Balance a Line:
l  Selecting the machines and/or adjusting the speeds
and starting times so that they operate together to
produce a smooth flow;

l  Conveyors, accumulators, and feed control systems


can be used to store excess production and
compensate for unevenness in the flow when one of
the machines is shut down for short periods of time
Material and Container Characteristics

1. Converters:
Many packaging materials and containers are prepared for
the packaging line by the converters who supply the
material;

[Example]
l  The converters: laminate film, foil, or other web
materials, apply protective coatings, and print them
ready to load onto a machine that makes bags for
packaging a particular product;
Material and Container Characteristics

2. Container Characteristics
Selecting a new container or changing the design of an
existing one can have several effects on the operation of
the machinery in a packaging line.

When the container design is changed, the following


should be considered:
l  Cost
l  Speed
l  Quality
Material and Container Characteristics

2. Container Characteristics
Example: Changing a syrup container from a round can
with a center neck to a rectangular can with the opening at
one end may produce a package that is more attractive /
easier to use / increase sales

However, it can also result in a more expensive container


that:
l  is difficult to orient on the line / reduces machine speeds
l  increases spillage
l  requires purchasing a new labeler
Material and Container Characteristics

2. Container Characteristics
That is, it may be a very advantageous change, or it may
cost more than it is worth.

Failing to consider all the variables that are operating in a


packaging line can result in undesirable decisions.
Material and Container Characteristics

3. Material Characteristics
l  Film and other web materials may have a tendency to
tear, or stretch;
l  The thickness of the material and its coatings can
drastically change its machinability;
l  Changing from a lightweight material to a heavier one
may cause problems if the machine is not adjusted for
the new material;
l  Improper storage can make some packaging materials
difficult to handle;
Material and Container Characteristics

3. Material Characteristics
[Example]
a. Folding carton blanks and other paper and paperboard
products warp and become difficult to run when they
are exposed to excessive humidity;

b. Some laminated web materials are so sensitive to


moisture and temperature changes that they are
stored in climate-controlled rooms during extreme
weather conditions.
Personnel
A surprisingly large number of people in different types of
jobs make decisions and initiate actions that affect the
operation of the packaging line:
l  The operators of the production line determine the
amount of product that the packaging line will receive,
the rate and evenness of the product flow, and the
consistency of the product's handling characteristics;
l  The packaging machine adjuster sets up the
machine and makes the adjustments that control its
operation;
l  The inspector determines when the packages are not
acceptable and machine adjustments are needed;
Personnel
l  The packaging machine operator controls the minute-
to-minute operation;
l  The packaging machinery mechanic troubleshoots and
repairs the machine when it is not functioning properly;
l  The scheduler determines the sequence of jobs and the
need for changeovers;
l  The packaging line supervisors oversee the operations
and decide who will work and when;
l  Packaging engineers or packaging specialists select
the package designs and materials and influence the
selection of the machines that will be included in the
packaging line
Personnel
l  Salespeople produce orders that enable the line to run;
l  The purchasing department buys the packaging
materials and containers;
l  The materials handler keeps the line supplied with the
materials as they are needed

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