For some companies, change is not just a technological upgrade: it is a change of mindset. Such is the case with one of our customers who decided to abandon an old semiautomatic line and switch to a vertical packaging machine of a new generation. Their goal? To improve productivity, optimize packaging formats, and pave the way for competitive industrialpackaging for future markets as well.
The challenge was twofold: first, to reduce the time and inefficiencies typical of manual handling; and second, to design a sack format capable of supporting the company's growth in the coming years, both in terms of logistics and product presentation.
Initial analysis: how to identify strategic formats for future packaging
The first step was listening. During initial visits and meetings, we gathered information about current products and those that the client considered strategic for the future. Often, at this stage, issues emerge that the company itself did not perceive as such, simply because they were considered "part of the process."
We then analyzed, together with the technical department, which formats made the most sense not only in the immediate but also in the medium to long term. The proposed packaging machine was chosen based on three key parameters:
- Ability to handle a wider range of formats than the previous line.
- Increased production line availability even with format changes.
- Accuracy in dosing to reduce waste and ensure uniformity.
From semiautomatic line to automatic vertical packaging machine: the tangible benefits
The transition to the packaging machine brought immediate benefits. It was not only a matter of speeding up production, but of ensuring consistent quality and greater reliability of operations.
Thanks to the automation thus introduced, order management became smoother, downtime was reduced, and the company was able to plan more complex productions without fear of bottlenecks. The ability to handle multiple references with a single machine represented a huge leap in efficiency.
How a bag format optimized for aesthetics and logistics is created
One of the most delicate aspects of a packaging machine project is the choice of format. In this case, we conducted tests with pre-sampling of the main products, checking the density of each.
Next, we conducted a 3D simulation to predict how the format would behave on pallets of different sizes and during transport. The goal was twofold: to ensure a bag that was stable and easy to palletize, but also aesthetically proportionate and pleasing to the end consumer.
A bag that is too oblong risks tipping over, while one that is too stubby may be unattractive on the shelf. The chosen format struck the right balance between logistical needs and commercial appeal.
Pre-testing and practical testing: the key step before final production with our automatic packaging machines
The pre-testing phase at our site was crucial. With the automatic vertical packaging machine already calibrated, the customer was able to see the actual result of the chosen formats live, touching the quality of the seals and verifying the stability of the packaging.
This step has made it possible to considerably reduce the risk of having to modify expensive mechanical elements after production start-up. It is an approach we always recommend, especially when working on customized industrial packaging .
Concrete results: more efficiency, less waste and greater competitiveness
Today, the customer benefits from an automatic vertical packaging machine that offers:
- Flexibility in formats, with fast and accurate changes.
- Reduction of waste through accurate dosing.
- Increased production speed and business continuity.
- Improved product presentation, positively impacting sales.
This was not just a technological improvement, but a true strategic evolution: from reactive packaging to proactive packaging, capable of sustaining business growth over the years.
Want to find out how a custom packaging machine can revolutionize your production process? Learn more about industrial packaging and contact our team from the contact page for a dedicated consultation.
