How Can I Modernise My End-of-Line Packaging?

Introduction

Manufacturers have many reasons to modernise production lines: productivity, flexibility, responsiveness and better working conditions for operators. But how should an end-of-line packaging modernisation project be approached? How do you choose the right partner, and which end-of-line operations can be automated most easily? This article outlines the main points to consider.

Changes in consumer and business purchasing behaviour have increased expectations for product personalisation, more local manufacturing, shorter delivery times and shorter supply chains that can reduce environmental impact.

Manufacturers therefore need production lines that can respond to these changing requirements. Today’s production equipment increasingly needs to:

• switch between product ranges quickly;
• adapt to different product and packaging formats on demand;
• deliver products with extremely low non-conformance rates;
• reduce the time between production, packaging and dispatch;
• and respond flexibly to future requirements.

These challenges make production-line modernisation increasingly important, particularly at the end of the line where many operations can still rely heavily on manual work.

Whether through robotics or special-purpose machinery, automation can help manufacturers improve flexibility, responsiveness and competitiveness.

Which end-of-line operations can be automated?

A large number of operations may be carried out at the end of a production line. Many are still assigned to operators and rely on manual actions, but most can be automated to improve productivity and reliability while reducing operator exposure to repetitive or physically demanding tasks. Commonly automated operations include:

• cartoning;
• end-of-line packaging, particularly case packing;
• visual inspection;
• marking and labelling;
• palletising.

By removing tiring, risky or highly repetitive tasks, manufacturers can reassign operators to higher-value work such as supervising several automated stations, preparing format changeovers or coordinating production.

The main stages of end-of-line modernisation

A partner supporting an end-of-line modernisation project will generally need to work through several key stages:

• analyse the existing equipment, production constraints and environment, involving project managers, technical teams and operators;
• develop concrete proposals covering technical choices, budget and project planning;
• prototype and validate solutions using digital models, gripping tests, equipment-supplier selection and virtual integration into the future environment;
• manufacture the end-of-line machine or packaging cell and integrate complementary equipment such as robots, cameras, readers and marking systems;
• install and commission the equipment on site with automation engineers, electricians, programmers, roboticists, operators and maintenance technicians;
• ramp production up progressively and train operators and technical teams;
• provide long-term support, maintenance and on-site assistance when required.

Why the choice of integration partner matters

Because these projects are technically complex and can have a major impact on end-of-line packaging operations, choosing the right partner is critical.

Mutual trust, the ability to listen and understand production issues, technical creativity, multidisciplinary engineering capability, customer references, financial stability, end-to-end project management and the number of interfaces involved are all points worth assessing before making a decision.

End-of-line automation projects can run for several months and involve human, technical, financial and organisational constraints. Manufacturers therefore need a reliable partner with relevant experience and the ability to manage these factors together.

Funding an end-of-line modernisation project

Depending on the country, region and timing of the project, public bodies or economic-development organisations may offer funding mechanisms for industrial modernisation and automation.

In France, programmes such as France Relance and France 2030 have supported industrial transformation and robotics projects. Available schemes change over time, so companies should verify current eligibility and application conditions before planning funding into a project.

Further reading: France 2030 and industrial robotics

Local or regional organisations may also provide grants, loan guarantees, reduced-rate financing or other support for investment in industrial equipment.

Companies can contact their local chamber of commerce and relevant regional industrial-development organisations to identify current support schemes.

Are you assessing a project to modernise your end-of-line packaging? If you want to improve productivity and reduce manual operations for packaging and inspection, JYGA can help define concrete automation options based on more than 30 years of end-of-line experience.