Process automation in packaging

The use of machines in packaging is always a big topic – whether at trade fairs or in discussions with our customers. Many companies see great advantages in automating their packaging processes; by optimising processes within logistics, especially in packaging, they can increase their productivity, save money on materials and reduce their impact on the environment. The following applies: Packaging machines are not only suitable for large companies with high stock turnover. Some machines are already worthwhile for small needs.

With the following guide we want to give an introduction into the world of packaging machines and present the advantages of the machines available at RAJA.

Why optimise packaging processes?

Filling cartons with cushioning material and strapping or wrapping pallets with stretch film, all these processes take time and can be made faster, cheaper and more efficient with machines. If more than 10 parcels have to be packed per day, it is worthwhile to purchase a packaging machine to save time and money.

Some of the advantages of machines:

• Acceleration of the packaging and storage processes and thus an increase in efficiency.
• Reduction of material use and thus waste production, which in turn// means cost reduction
• Saving space in the warehouse, for more storage space or to increase productivity
• Reduction of the company’s impact on the environment
• More control over the packaging process, improving productivity and flexibility

What is the advantage of a packaging machine?

At RAJA, packaging machines are categorised into 3 different areas according to their functionality:

Padding and filling machines

For every company it is essential that the goods arrive safely and undamaged at the respective destination. In order to optimally protect loose goods during shipping, paper pads or an air cushion filling are ideally suited to protect the goods.

Cushioning and filling machines produce void fill easily and quickly exactly as and when it is needed. This eliminates the need to purchase pre-made cushioning material such as bubble wrap on rolls or packing chips. The packaging material for the machines (such as plastic or paper) is supplied in economical rolls, which means a saving in transport costs and allows more storage space. For comparison, 7 rolls of the Fill-Air Rocket air cushion system is equivalent to a truck full of bubble wrap.

Air cushion machines

These compact machines produce air cushioning for padding and protecting goods in the carton. Simply place the roll of film on the machine’s spindle, select the cushioning programme and produce as much cushioning material as is needed.

The Mini Pak’r can be used almost anywhere thanks to its compact size. Easy to handle, cushioning material is produced quickly and efficiently. This makes the machine ideal for small and medium packaging requirements.

For larger packaging quantities, machines such as the Fill-Air Rocket™ or the New Air I.B. Express are suitable, they can also produce large quantities of air cushion pads.

Paper padding machines

Paper cushioning machines are very cost-efficient and environmentally friendly. In addition, studies have shown that consumers prefer paper packaging materials because of environmental concerns. The machines produce stable corrugated paper snakes from stacks or rolls of paper, which are suitable for wrapping, protecting, fixing or filling cavities in packages.

Paper cushioning machines are ideal for large quantities of packages (up to 1.4 metres of paper are produced per second). They are larger than air cushioning systems, but also offer greater flexibility. With a volume of more than 50 packages per day, the purchase of a machine is already worthwhile, as it leads to a material saving of 30% within the first 3 months.

Paper padding machines are available in different sizes depending on your needs and budget. Depending on the design, individual models have control panels, foot pedals and paper length programming.

The less expensive models, such as the FillpakM, are suitable for small packaging needs. Paper is dispensed via a hopper, allowing complete control over the amount of padding material required. For medium demand, the PadPak Junior is very suitable and can be integrated into packaging lines with at least 30 items per day.

Fully automated, machines like the PadPak Senior are ideal for large volumes and for fast packaging lines, as they guarantee a paper flow. Paper lengths can be preset and the right amount of filler is continuously dispensed.

The machine guide for filling and upholstery machines

As a small selection aid for filling and cushioning machines, we offer a packaging systems guide on our website. By answering a few questions, you can use it to find the right machine for your needs.

Machines for securing and sealing

Once the products are placed in the carton, the carton must be well secured and sealed whether it is shipped individually or on a pallet.

Closing machines come in two types:

• Strapping equipment to seal cartons and large goods tightly and securely
• Stretch wra ppers to wrap pallets tightly with film to secure them.

Strapping machines

When goods are shipped that need to be additionally secured, strapping is usually used. Strapping machines automate the strapping process manually, they take over the tensioning of the strap around the package, as well as the sealing and the strap cutting quickly and effectively. A machine can unstrap a carton in under 10 seconds and semi-automatic strapping machines allow hands-free operation with the foot pedal.

Stretch wrapping machines

Stretch wrapping machines can wrap a pallet loaded with goods with stretch film. The speed varies, depending on the design of the machine. From entry-level models that can be easily commissioned to industrially programmable machines that can be specially adjusted to individual requirements.

With a stretch wrapping robot, you have maximum flexibility. Very versatile, this robot can strap products of any size and variant.

Stretch wrapping machines are particularly suitable for companies that ship large quantities of palletised goods. If they have to strap more than 50 pallets per day, stretch wrapping machines can speed up their processes.

Small helpers with a big effect

Especially when it comes to sealing, the use of machine support is worthwhile even for small requirements. Sealing is usually not that easy, especially tape dispensers require a lot of practice for an optimal result. Here, too, there are devices that simplify carton sealing. With the battery-operated Bostitch carton sealer, for example, 2-3 corrugated cartons can be sealed easily and securely; like hand strapping tools, it can be used flexibly. Wet adhesive tapes are also a good option and can be conveniently applied to the carton with electric table dispensers or adhesive roll moisteners. Hot glue guns are also suitable for sealing cardboard boxes. Individually printed cardboard boxes, for example, are not covered in this way. The seal is particularly long-lasting and also suitable for heavy loads and export, as the seal is resistant to temperature fluctuations from -10°C to +75°C.

Read more about securing and sealing with machines

Machines for film processing

Film processing machines include all shrink and welding devices. They are designed to pack and seal goods in bags or pouches. They are packed in PVC or shrink film and are thus protected from dust and dirt during storage or from damage during transport or in the display.

Both shrink and sealers can produce bags of almost any size. For smaller products such as jewellery or electronic items, CDs or books, through to bulkier items (usually up to 800mm wide). There are many advantages to making your own bags: different bag sizes can be made depending on the order and the material can be stored on site so that the bags are at hand when they are needed.

• Shrink wrapping equipment

  Shrink wrappers are particularly suitable for packaging and displaying products in the retail trade, for example large books, mirrors or pictures. The shrink wrap creates a puncture resistant film shield that protects items from water and dust.

• Welding equipment

  Welders can be used to seal large quantities of bags quickly and easily. Small and compact, they fit into existing packing processes and can be placed on a stand with a foot pedal for hands-free operation. The machines with welding arm work with an integrated cutter and save time when smaller products need to be packed into bags.

Read more about Welding, Shrinking, Vacuuming

Buy, rent and maintain

Buying a machine usually means a large purchase investment, especially for small or medium sized companies this can become a problem. Therefore, many of our packaging machines are also available for rent, without high acquisition costs. However, the machine should always be tested before purchase.

If the machine is not working or needs to be repaired, an appointment will be made immediately with our technician at your site to ensure that the downtime in the workflow is minimal.

Conclusion

Investing in a packaging machine not only means savings in terms of purchasing previous padding material, because up to 3 times as much storage space is saved in the warehouse. The same applies to the speed as well as the productivity of the packing process – meaning that orders can be shipped faster.

For more information on the subject of packaging machines or for a no-obligation demonstration of a machine, contact our machine experts on: 0800 / 20 77 060 or by email at grosskunden@rajapack.de.