Find the visible problem
Moving to automation in packaging production
Automate the limiting operation without creating a new bottleneck. Start with measured evidence, identify the first loss of control and then use the relevant answer for your product, pack or process.
197specific questions
10production areas
5core diagnostic checks
1measurable result: labour and capacity improvement
Start with these checks
Automate the task that limits output, quality or labour efficiency first.
- Map the current process and operator movements
- Measure cycle time, waiting, rejects and replenishment
- Identify the constrained step and the next likely constraint
- Compare one-step, cell and full-line automation
- Include changeover, cleaning, guarding and support in the return calculation
Common underlying causes
- A fast machine being added while loading or downstream packing stays manual
- Insufficient buffers between processes with different stop patterns
- The product or packaging not being presented consistently
- Automation being designed around average demand instead of the full product mix
How to use this section
Open the production area below, then choose the question that matches the product, pack or operation. Record the result of each check before changing another setting.
Choose the closest production area
Search these answers →197 answers about moving to automation
Liquid filling 15 answers
Troubleshoot thin, foamy, viscous, carbonated, corrosive and flammable product filling.
How do I automate filling, capping and labelling for thin free-flowing liquids?How do I automate filling, capping and labelling for foamy liquids?How do I automate filling, capping and labelling for viscous liquids?How do I automate filling, capping and labelling for carbonated drinks?How do I automate filling, capping and labelling for hot-fill liquids?How do I automate filling, capping and labelling for chilled liquids?How do I automate filling, capping and labelling for edible oils?How do I automate filling, capping and labelling for syrups?How do I automate filling, capping and labelling for sauces and dressings?How do I automate filling, capping and labelling for creams and lotions?How do I automate filling, capping and labelling for gels?How do I automate filling, capping and labelling for liquid suspensions?How do I automate filling, capping and labelling for corrosive chemicals?How do I automate filling, capping and labelling for flammable liquids?How do I automate filling, capping and labelling for solvent-based products?
Powder and piece filling 18 answers
Solve variable weights, dust, bridging, segregation, breakage and hopper-feeding problems.
How do I automate weighing, filling and sealing for fine powders?How do I automate weighing, filling and sealing for dusty powders?How do I automate weighing, filling and sealing for cohesive powders?How do I automate weighing, filling and sealing for free-flowing powders?How do I automate weighing, filling and sealing for flour?How do I automate weighing, filling and sealing for spices and seasonings?How do I automate weighing, filling and sealing for protein powder?How do I automate weighing, filling and sealing for milk powder?How do I automate weighing, filling and sealing for sugar?How do I automate weighing, filling and sealing for salt?How do I automate weighing, filling and sealing for ground coffee?How do I automate weighing, filling and sealing for seeds and grains?How do I automate weighing, filling and sealing for pet food pieces?How do I automate weighing, filling and sealing for granules?How do I automate weighing, filling and sealing for tablets and capsules?How do I automate weighing, filling and sealing for snack pieces?How do I automate weighing, filling and sealing for fragile food pieces?How do I automate weighing, filling and sealing for mixed-size pieces?
Pack formats 22 answers
Find answers for bottles, jars, tubs, cans, pouches, bags, cartons, cases, trays and tubes.
How do I automate a complete production line for round bottles?How do I automate a complete production line for square bottles?How do I automate a complete production line for oval bottles?How do I automate a complete production line for glass bottles?How do I automate a complete production line for PET bottles?How do I automate a complete production line for HDPE bottles?How do I automate a complete production line for jars?How do I automate a complete production line for tubs?How do I automate a complete production line for jerrycans?How do I automate a complete production line for metal cans?How do I automate a complete production line for vials?How do I automate a complete production line for premade pouches?How do I automate a complete production line for sachets?How do I automate a complete production line for doypacks?How do I automate a complete production line for spouted pouches?How do I automate a complete production line for open-mouth bags?How do I automate a complete production line for folding cartons?How do I automate a complete production line for corrugated cases?How do I automate a complete production line for trays?How do I automate a complete production line for tubes?How do I automate a complete production line for bottle rinsing before filling?How do I automate a complete production line for returnable bottle washing?
Capping and closures 18 answers
Diagnose leakage, cross-threading, variable torque, cap damage and closure-feeding faults.
How do I automate feeding and applying screw caps?How do I automate feeding and applying pump caps?How do I automate feeding and applying trigger sprays?How do I automate feeding and applying flip-top caps?How do I automate feeding and applying disc-top caps?How do I automate feeding and applying twist-off jar lids?How do I automate feeding and applying vacuum jar lids?How do I automate feeding and applying ROPP caps?How do I automate feeding and applying T-corks?How do I automate feeding and applying press-on caps?How do I automate feeding and applying snap caps?How do I automate feeding and applying child-resistant caps?How do I automate feeding and applying tamper-evident caps?How do I automate feeding and applying aluminium screw caps?How do I automate feeding and applying sports caps?How do I automate feeding and applying dropper caps?How do I automate feeding and applying stoppers?How do I automate feeding and applying bungs?
Labels and coding 18 answers
Resolve skew, wrinkles, bubbles, poor adhesion, unreadable codes and variable-data errors.
How do I automate applying and verifying round-bottle labels?How do I automate applying and verifying front and back labels?How do I automate applying and verifying full wrap labels?How do I automate applying and verifying tapered-container labels?How do I automate applying and verifying clear labels?How do I automate applying and verifying small labels?How do I automate applying and verifying large labels?How do I automate applying and verifying top labels?How do I automate applying and verifying base labels?How do I automate applying and verifying pouch labels?How do I automate applying and verifying carton labels?How do I automate applying and verifying shrink sleeves?How do I automate applying and verifying tamper-evident neck bands?How do I automate applying and verifying batch codes?How do I automate applying and verifying date codes?How do I automate applying and verifying barcodes?How do I automate applying and verifying QR codes?How do I automate applying and verifying shipping labels?
Flexible packaging 14 answers
Solve pouch opening, dosing, film tracking, contamination and seal-quality problems.
How do I automate dosing, sealing and coding for premade pouch filling?How do I automate dosing, sealing and coding for sachet filling?How do I automate dosing, sealing and coding for vertical form-fill-seal bags?How do I automate dosing, sealing and coding for flow-wrapped packs?How do I automate dosing, sealing and coding for pillow bags?How do I automate dosing, sealing and coding for quad-seal bags?How do I automate dosing, sealing and coding for stick packs?How do I automate dosing, sealing and coding for stand-up pouches?How do I automate dosing, sealing and coding for spouted pouch filling?How do I automate dosing, sealing and coding for vacuum pouches?How do I automate dosing, sealing and coding for zipper pouches?How do I automate dosing, sealing and coding for gusseted bags?How do I automate dosing, sealing and coding for shrink film?How do I automate dosing, sealing and coding for sleeve film?
End of line 13 answers
Improve cartoning, case sealing, shrink wrapping, case packing and dispatch inspection.
How do I automate product handling around case taping?How do I automate product handling around cartoning?How do I automate product handling around shrink wrapping?How do I automate product handling around sleeve wrapping?How do I automate product handling around L-sealing?How do I automate product handling around case packing?How do I automate product handling around tray packing?How do I automate product handling around pallet wrapping?How do I automate product handling around print-and-apply labelling?How do I automate product handling around checkweighing?How do I automate product handling around metal detection?How do I automate product handling around dispatch packing?How do I automate product handling around induction foil sealing?
Automation and conveyors 19 answers
Solve tipping, back-pressure, transfer, feeding, accumulation and line-integration problems.
How do I automate the handling of lightweight bottles?How do I automate the handling of tall unstable bottles?How do I automate the handling of glass containers?How do I automate the handling of flexible pouches on conveyors?How do I automate the handling of cartons and cases on conveyors?How do I automate the handling of small components?How do I automate the handling of caps and closures?How do I automate the handling of pumps and trigger closures?How do I automate the handling of mixed products on one line?How do I automate the handling of fragile products on conveyors?How do I automate the handling of wet containers?How do I automate the handling of sticky products and packs?How do I automate the handling of high-speed packaging lines?How do I automate the handling of multi-format packaging lines?How do I automate the handling of manual-to-automatic production?How do I automate the handling of complete filling and packing lines?How do I automate the handling of component bowl feeding?How do I automate the handling of production line accumulation?How do I automate the handling of automatic bottle unscrambling?
Industries 40 answers
Customer-focused answers for food, drink, health, chemical, industrial, packing and logistics operations.
Which parts of bottled water production should be automated first?Which parts of soft drink production should be automated first?Which parts of brewery packaging should be automated first?Which parts of cider production should be automated first?Which parts of wine bottling should be automated first?Which parts of spirits and distillery packaging should be automated first?Which parts of dairy production should be automated first?Which parts of plant-based drink production should be automated first?Which parts of sauce and condiment production should be automated first?Which parts of honey and preserve production should be automated first?Which parts of edible oil production should be automated first?Which parts of bakery ingredient production should be automated first?Which parts of snack and confectionery production should be automated first?Which parts of coffee and tea packaging should be automated first?Which parts of spice and seasoning production should be automated first?Which parts of pet food production should be automated first?Which parts of seed and grain packing should be automated first?Which parts of cosmetics manufacturing should be automated first?Which parts of skincare production should be automated first?Which parts of personal care production should be automated first?Which parts of pharmaceutical packaging should be automated first?Which parts of medical device packing should be automated first?Which parts of nutraceutical production should be automated first?Which parts of fragrance production should be automated first?Which parts of household cleaning production should be automated first?Which parts of industrial chemical packing should be automated first?Which parts of agrochemical production should be automated first?Which parts of paint and coating production should be automated first?Which parts of adhesive and sealant production should be automated first?Which parts of lubricant and automotive fluid production should be automated first?Which parts of construction powder packing should be automated first?Which parts of laboratory and technical liquid packing should be automated first?Which parts of contract packing should be automated first?Which parts of e-commerce fulfilment should be automated first?Which parts of warehouse dispatch should be automated first?Which parts of general component assembly should be automated first?Which parts of hardware and fixings packing should be automated first?Which parts of wet wipe and hygiene product packing should be automated first?Which parts of returnable bottle operations should be automated first?Which parts of recyclable packaging conversion should be automated first?
Planning and improvement 20 answers
Measure and improve production performance, safety, validation, maintenance, sustainability and investment decisions.
How can automation improve or measure line speed?How can automation improve or measure format changeovers?How can automation improve or measure planned maintenance?How can automation improve or measure production downtime?How can automation improve or measure product giveaway?How can automation improve or measure packaging waste?How can automation improve or measure operator workload?How can automation improve or measure overall equipment effectiveness?How can automation improve or measure machine safety?How can automation improve or measure hygienic design?How can automation improve or measure production traceability?How can automation improve or measure process validation?How can automation improve or measure ATEX and hazardous areas?How can automation improve or measure sustainable packaging changes?How can automation improve or measure second-hand machinery?How can automation improve or measure critical spare parts?How can automation improve or measure utility planning?How can automation improve or measure factory acceptance testing?How can automation improve or measure site acceptance testing?How can automation improve or measure return on automation investment?
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.
How should I use the Moving to automation in packaging production page?
Automate the limiting operation without creating a new bottleneck.
What information should I collect before comparing equipment for Moving to automation in packaging production?
Collect representative product and packaging samples, dimensions, format range, current and required good output, measurable tolerances, utilities, site layout and cleaning requirements.
Why should I test the hardest product or pack first for Moving to automation in packaging production?
The most difficult product, smallest dose, largest pack or least stable container normally exposes limitations that an easy sample can hide.
How should I compare two machinery routes for Moving to automation in packaging production?
Compare sustained good output, quality, changeover, cleaning, operator work, utilities, maintenance and the acceptance test—not only catalogue speed and purchase price.
When should I ask for a sample trial for Moving to automation in packaging production?
Ask for a representative trial before committing when product flow, foam, dust, particles, seals, labels, closures or pack stability could materially affect the result.