The introduction of automation and secondary packaging in packaging lines is a strategic investment for food companies in emerging markets.
The introduction of automation and secondary packaging in packaging lines represents a challenge and an opportunity for food companies, especially in emerging markets. Many packaging lines stop, in terms of automation, at primary packaging, which is obviously essential to get products onto the shelves.
The first temptation of a project manager is to automate to reduce the presence of operators on the line, but one must be aware of the impact this can have on the flexibility of the line. Manual operations offer a flexibility with which automated machines cannot compete except at a very high cost. When automating a line, the aim should be to increase production by reducing format variability.
Flexibility should be maintained by planning production and moving products that have less impact to dedicated or semi-automated lines. Another crucial aspect is space in the factory. Machines require operational space, both in terms of floor space of the machine itself and for operation, maintenance and material flow.
It is essential to carefully plan the layout of the production line to ensure that new machines do not obstruct the workflow and that there is sufficient space for maintenance and operation.
Connections to the product warehouse are another key point. Increased production means an increased flow of materials. The use of manual palletising and handling with pallet trucks may not be sufficient. Automated solutions for warehouse management and the transport of finished products must be considered in order to avoid bottlenecks and ensure a continuous and efficient flow.
Ergonomics of the line is crucial to ensure the safety and efficiency of operators. The addition of new machines and connecting conveyors, if not carefully planned, can close off passages for operators and make the flow of packaging materials to the machines more difficult. The layout must be carefully planned to ensure that operators can work safely and that material flow is optimised.
Finally, it is important to consider the implementation steps. Automating a line in a one-off solution can disrupt or even stop production for weeks, if not months, while work is completed. If possible, although more costly, it is a good idea to plan the work not in a single solution, but in successive steps, in order to validate each step and allow the operators to learn the new project management methods. This step-by-step approach minimises risks and ensures a smoother transition to automation.
In conclusion, the introduction of automation and secondary packaging in packaging lines is a strategic investment for food companies in emerging markets. The benefits in terms of flexibility, efficiency, quality, safety and sustainability are obvious. However, it is essential to carefully plan every aspect of the transition process. M.H. Material Handling is at its customers’ side in this process, supporting them from the very beginning of the projects.
