Solving Packaging Challenges in CPG Operations
As production demands increase, even minor issues can create slowdowns, variability and missed targets. After 60+ years of addressing packaging challenges, here are the root causes we’ve identified and the best approach to fixing them.
Talk to a Packaging ProfessionalThe Challenges
Where Packaging Lines Typically Struggle
While every CPG operation is unique, many manufacturers face the same common issues. Knowing their underlying cause is the first step towards defining a solution.
If your end-of-line equipment isn’t performing the way you need, check out these problem categories and the paths you can take towards simpler, more productive packaging.
Unplanned Downtime
The Challenge:
Unexpected stops disrupt production and make it difficult to hit targets. Common causes include:
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Jams or misfeeds
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Inconsistent product flow
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Line imbalances
How This is Addressed:
Improving product handling and simplifying system design can reduce the conditions that lead to jams and repeated stoppages. When equipment works together more predictably, downtime becomes less frequent and easier to manage.
Learn More About Reducing DowntimeTime-Consuming or Complicated Changeovers
The Challenge:
Lines that run multiple SKUs require changeovers and these can slow everything down, especially if they are overly complex or manual. Common causes include:
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Large number of manual adjustments
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Time lost dialing in settings
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Increased risk of operator error
How This is Addressed:
Simplifying adjustments and designing for flexibility across products helps make changeovers faster and more repeatable. The goal is to reduce time between runs without adding complexity.
Learn More About Reducing Changeover TimeLabor & Safety Challenges
The Challenge:
Manual and repetitive processes put a strain on your team and introduce variability or injury risk. This often shows up as:
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Repetitive tasks that lead to fatigue or injury
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Difficulty staffing consistently
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Inconsistent outcomes based on labor availability
How This is Addressed:
Reducing manual touchpoints and improving ease of operation helps create a more consistent process while easing the burden on operators. In many cases, targeted automation can make a meaningful difference.
Learn More About Hidden Ergonomic ProblemsInconsistent Performance
The Challenge:
Even though your equipment is running, various factors prevent consistent results. This is often related to:
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Bottlenecks between machines
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Packaging material variability
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High reject rates
How This is Addressed:
Looking at the line as a whole helps improve flow and consistency. When systems are aligned and integrated, performance becomes more predictable.
Learn More About Machine EfficiencyThe Solution
How We Can Help
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Simpler Systems, Fewer Issues
Equipment is designed for straightforward operation and maintenance, helping reduce variability and unnecessary complexity.
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More Predictable Performance
Systems are built to handle real production demands with fewer adjustments and interruptions.
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Faster, More Repeatable Changeovers
Changeover processes are streamlined, making them easier to execute and reducing time between runs.
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Reduced Reliance on Manual Processes
Automation and thoughtful system design help minimize operator intervention while improving consistency.
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Stronger Line Integration
Equipment is engineered to work together, improving flow and reducing bottlenecks across the system.
Let’s Take a Closer Look at Your Line
Share a few details about your operation. We’ll help you identify what’s holding performance back and how to start moving it forward.
