HTPHow to PackageProduction answers by Lancing UK
Automation and conveyors

How do I reduce damage and rejects with multi-format packaging lines?

Practical guidance for multi-format packaging lines: reduce product loss, damaged packs, film waste and avoidable rejects.

Answer format: direct explanation, ordered checks and relevant solution routes. . Application-specific engineering review is still required.

Direct answer

For multi-format packaging lines, measure where material or product is lost and calculate waste per good pack. Stable automation depends on positive product control, compatible machine rates, enough accumulation and a clear control philosophy for stops and restart. Start by separate product, packaging and rework waste and record jam frequency, blocked and starved time, product damage and sustained line output. Make one controlled change at a time so the original cause is not hidden by several new settings.

Production environment relevant to automation and conveyors
Work safely: Isolate machinery before inspection or clearing. Follow the machine manual, site procedures and competent-person requirements.

What usually causes this?

  • overfilling, over-application or excessive trim used as a safety margin
  • A change in product orientation and stability or guide and transfer geometry.
  • start-up and changeover settings not standardised
  • The equipment or handling method not being set for equipment required to run a broad product and pack matrix.
  • damaged or misfed packaging creating repeated rejects

Checks to make in order

  1. Separate product, packaging and rework waste
  2. Record jam frequency, blocked and starved time, product damage and sustained line output using a representative sample.
  3. Weigh or count loss during start-up, running and changeover
  4. Check upstream and downstream speed relationship, sensor and control handshakes and accumulation, access and fault recovery.
  5. Record the reason for every reject in a sample period
  6. Check whether waste changes with speed or pack size
  7. Calculate the financial value of giveaway and damaged packs

How to decide the next step

Multi-format packaging lines involves equipment required to run a broad product and pack matrix. Prioritise the largest measured loss, then verify that the change does not reduce seal, dose or closure quality.

If adjustment and maintenance cannot hold the required result across the complete product and pack range, compare the machinery route against a written acceptance test. The important comparison is sustained good output—not only maximum cycle speed.

What to include in your production brief

Supplying the information below makes it much easier to distinguish a setup problem from a machinery or packaging limitation:

  • Product and pack samples
  • Scaled line layout
  • Current cycle and stop data
  • Minimum and maximum format
  • Upstream and downstream interfaces
  • Target sustained output
  • Samples that represent multi-format packaging lines
  • A short video of the current process and fault

Relevant solution websites

These specialist sites match the production process discussed above. Final suitability should be confirmed with samples, output, site and acceptance information.

Packaging ConveyorsPackaging Automation UKAutomation Machinery

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Common search questions

Questions customers also ask

Open a question for a concise answer, then use the detailed guide above for the full production checks.

What should I check first for multi-format packaging lines?

Separate product, packaging and rework waste

What commonly causes this problem with multi-format packaging lines?

Common causes include overfilling, over-application or excessive trim used as a safety margin; A change in product orientation and stability or guide and transfer geometry.; start-up and changeover settings not standardised.

How can I prove that an adjustment has worked for multi-format packaging lines?

Record a representative baseline, change one variable at a time and repeat the same measurement over enough packs to show that the result is stable rather than a one-off improvement.

When should I consider a different machine or production method for multi-format packaging lines?

Consider a different route when correct setup and maintenance cannot hold the required quality and sustained output across the complete product and pack range.

What information should I send before asking for a solution for multi-format packaging lines?

Include Product and pack samples; Scaled line layout; Current cycle and stop data; Minimum and maximum format.

Which solution website is most relevant to this question?

The clearest starting point on this page is Packaging Conveyors. Final suitability still needs to be confirmed using the actual product, packaging, output and site information.