Why packaging lines need modularity

In modern packaging facilities, agility has become key to productivity. Using a plug-and-play approach, manufacturers can introduce modularity into their packaging automation and benefit from the flexibility it offers

Automation is not new, with industries such as pharmaceuticals, medical technology and food and beverage all benefiting from automated pack-and-place, labelling and case-packing systems. Some have even utilised vision cameras to inspect their products and reject those that do not meet the grade.

Traditionally, packaging lines were created for specific products and throughputs, which can be effective for long production runs. However, they are rigid, and even minor changes, such as adding a new pack size or switching materials, can require extensive reengineering- resulting in downtime and added costs.

Modularity

When going modular, manufacturers can treat their packaging lines as a series of self-contained units, such as sealers, labellers, and carton erectors, that they can connect, remove, and replace when needed. Using plug-and-play, new modules can be quickly recognised by the control system with minimal configuration.

This flexibility is an advantage, as many production and packaging lines are facing increasing stock-keeping unit counts, seasonal campaigns, and growing demand for personalised and sustainable packaging, making the ability to reconfigure lines without disruption a welcome benefit.

As packing requirements change due to regulatory changes, material availability or changing demands, modular systems provide a cost-effective way to be flexible. Instead of investing in an entirely new line, manufacturers can add and swap modules incrementally, extending the usable life of their existing equipment while maintaining their competitive edge.

Automation

These modular packaging lines are centred around sophisticated automation technologies that support the integration of individual processing units. For example, manufacturers can combine PC-based control systems with real-time communications networks such as EtherCAT. Using this setup enables manufacturers to have several modules, such as sealers and labellers, working independently while sharing data with the central control system.

Something else to consider is the use of standardised communication protocols and open control architectures that enable interoperability across different equipment supplies, which can help manufacturers to easily scale their packaging lines. By avoiding vendor lock-in, they can upgrade and modify different sections and parts without redesigning the entire control infrastructure.

This level of automation also supports predictive maintenance, remote diagnostics, and centralised monitoring, improving uptime in already-stretched packaging lines.

Modularity and sustainable packaging

Several companies are under pressure to reduce waste, lower energy consumption, and use more sustainable packaging, such as biodegradable and recyclable packaging. These changes can be challenging with fixed lines, where even minor material substitutions require a full system redesign. Sealing temperatures, cutting tolerances, and product handling may need adjustment, resulting in downtime and material waste during setup.

A modular approach provides a more agile solution. Manufacturers can make targeted upgrades to accommodate new materials, such as recyclable film, and avoid scrapping entire systems, enabling the phased implementation of greener packaging options.

Packaging lines are known for being rigid, but modularity can provide some flexibility. These facilities have to adapt to keep up with changes in customer demand, regulations, and attitudes towards packaging materials. By going modular and using a ‘plug and produce’ approach, they can do this incrementally and cost-effectively.

To find out more about how PC-based technology and EtherCAT can improve packaging machine automation, download this white paper.

Contributed by Mark Richards, regional manager at Beckhoff UK.