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April 11, 2024
Downtime: the archnemesis of uptime. When your packaging and shipping department experiences downtime, it can bring your entire operations to a screeching halt. This, in turn, results in prolonged deliveries, customer dissatisfaction, and a significant loss to your bottom line.
Packaging downtime is an unfortunate inevitability for any company. However, there are several ways you can minimize downtime so your business can perform at the optimum level. In this highly functional article, we will cover four ways you can keep packaging downtime at bay.
Practice Preventive Maintenance
A common phrase you’ll hear in health care is “prevention is better than cure”. The same principle applies to your company’s packaging operations: preventing downtime is a lot easier—and cheaper—than resolving it.
Like with any machinery, your packaging equipment can only run continuously for so long before they start to develop problems. And if you’ve got older equipment, they’ll develop their problems sooner than later. To combat this, schedule inspections on a weekly to monthly basis to examine the condition of your equipment.
Make sure you also set up comprehensive maintenance checklists so that each and every component of your equipment is verified to be in top working order. At the same time, make sure your maintenance team is given enough time to thoroughly check over the machines and provide detailed records of their maintenance checks.
Measure Optimum Output During Uptime
You may learn more from your failures than your successes, but your successes still provide some worthy insight into how your operations should function. When your packaging and shipping operations are running smoothly, develop some key performance indicators (KPIs) and take measurements on how things are performing.
When developing your KPIs, ask yourself the essential questions: how many packages or pallets are shipped out an hour, or a day? How long does it take for an item to go through the entire packaging department? Are there any areas or systems that can be improved to increase your output?
With a solid set of KPIs and careful measurement of your operations, you can determine what optimal output looks like so that when downtime strikes, you’ll notice it immediately and then determine the source of the downtime more easily.
Have Spare Parts Stocked Up
Even the best-made plans can go awry. Machine parts, especially those in constant motion, will wear down over time. These old and faulty parts will impair the machine’s performance, or worse, break it. When your parts are well past their prime, they need to be replaced.
A stockpile of spare parts can be a lifesaver in moments of downtime. Thankfully, most manufacturers of industrial equipment are more than willing to sell replacement parts for their machines. Just make sure you have the manual or reference guide with parts numbers at the ready so that you can request the right parts.
Plan Your Budget for Upgrades
Nothing lasts forever, especially not industrial machinery. When your packaging equipment reaches the end of its operational lifespan, it needs to be replaced. However, industrial equipment can be incredibly expensive and perhaps unfeasible if you cannot budget for it.
If maintenance discovers that a piece of equipment is on its way out during a routine maintenance inspection, or the equipment is getting close to the manufacturer’s recommended lifespan, plan early for expensive upgrades. At the beginning of the fiscal year, set aside a percentage of the yearly budget to go exclusively to upgrades and repairs.
A new piece of industrial equipment can be costly, but a critical failure will be costlier.
Cut Down Your Downtime
Life comes with three guarantees: death, taxes, and downtime. Even the world’s most successful businesses, like Amazon, Apple, and General Motors, will encounter packaging downtime that can stop operations in their tracks. The name of the game isn’t making sure you never have downtime—it’s keeping downtime to an absolute minimum.
Preventative maintenance and spare parts are crucial for addressing downtime in the heat of the moment. At the same time, taking measurements during uptime and planning for upgrades can go a long way toward staving off future downtime as much as possible. Your ability to handle downtime all comes down to how prepared you are for it.
For further reading on managing your packaging operations, be sure to check out our article on why you may need to improve your operations with a stretch wrap machine.
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July 13, 2023Wondering how to make the most and safest use of space on your pallets? Here are the best ways to pack a pallet for shipping in six easy steps.
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October 04, 2021Do you do a lot of business by mail and are worried about the security of your stuff? Here are a few tips for keeping your product secure during shipping.
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September 30, 2021Doing a lot of business by mail but want to go greener with your shipping options? Here are a few eco-friendly mailing solutions for e-commerce orders.
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July 29, 2021Here are some of the best ways to package clothing for shipping. Online shopping is all the rage right now and its popularity doesn’t seem to be slowing.
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February 04, 2019
Heat sealers are machines that are used for mending both the sides of packaging film together so that it forms an air tight seal. The heat sealers use heat to melt and mend materials together to form a seal. However, it is necessary to understand what materials can be used with the heat sealers. Also, you need to determine the thickness of the packaging film to be used with specific type of sealers.
Common Materials
Many products are sealed using a heat sealer. Most of the flexible materials are measured in mils. Materials that are 1-3 mils thick are considered standard. Materials ranging from 4-8 mils of thickness are medium to heavy. The thicker materials need more heat and thicker seals to mend the material together properly.
Types of Heat Sealers
There are two varieties of heat sealers available on the market - flat wire and round wire. The former is designed for thicker films that are up to 8 mils thick while the latter have thinner seal seams and are generally used for thinner materials.
Round wire sealers - These offer certain benefits over the flat wire sealers. The round wire sealers cut excess film once the seal is done and they also have thinner seal seams that look better. These sealers are often used with Shrink Wrapping. A drawback to the round wire sealers is that they form a thin seal that limits the strength of the seal. They cannot make proper, reliable seals with films thicker than 4 mils.
Flat wire sealers - The flat wire sealers are available in a variety of widths and can be conveniently used with thicker films carrying heavier products. These make a strong, full seal and leave the excess film on the bag itself which can either be used for hanger holes or custom printed headers. They can also be embossed for an added strength to the seal. The only disadvantage with the flat wire sealers is that it doesn't cut down the excess film from the package. In case the film needs to be cut, you would require a separate cutter to do the job.
Depending on the products you must pack, you can now determine which heat sealer would work best for you to refrain from packaging disasters and a bad customer experience.
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January 07, 2019
It is important to understand the temperature limits of your Packaging Material when it comes to packing hot or cold items in a specific form. While many times it is a matter of confusion whether a foam container is safe to go into the microwave or the oven-safe container is safe to be kept in the freezer, here is a helpful guide to understand the temperature limits of your packaging containers.
Polystyrene (Foam) Cups, Containers, and Dinnerware
Foam characterizes excellent insulation properties and also has thermal resistance to some extent which makes it fairly applicable to both hot as well as cold foods. It keeps hot foods hot and cold foods stay cold in a foamed polystyrene container. Polystyrene is a sustainable packaging material that is also popular for its versatility and affordability.
Polypropylene Containers
Polypropylene is the best choice of material when it comes to microwave safe packaging. As the material offers high resistance to heat, it does not get warped in the microwave. PP is now accepted by curbside recycling programs too.
PET
PET is a solid plastic that is most often used in the bottling of water and soda. The versatile substrate is widely accepted by municipality curbside recycling programs. IT comes in two variants - APET & CPET. APET is known to enhance the shelf life of food products with an expiry date. APET is a perfect choice for confectionery items, cookies, pastries, natural snacks, cold drinks and more such items. CPET is a crystallized form of PET that has the capacity of withstanding very high and extremely low temperatures. So, this material can be safely used in the microwave and even in the freezer as it withstands temperatures of up to 400°F.
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December 17, 2018
Modern packaging necessities lead manufacturers and other companies to consider thorough research when it comes to selecting a packaging materials supplier. Packaging is a complex area and you need the right players to hit the ball high.
Let us go through a checklist of things to be considered before making a choice.
- Selection of materials
First, you need to assess whether the supplier deals with the materials you would require for your product packaging. Also, an important thing you need to know is whether they always have the stock when you need it. Do they source the required material in definite quantities as requested?
Is your item seasonal?
Some items are sold in specific seasons. Your supplier must be able to cope up with your seasonal material needs.
- Pricing
Pricing should be judged on two parameters - quantity & quality of the packaging material in comparison with that of other competitions. Here you must be clever enough to analyze on a higher perspective like customer service and delivery times rather than only considering the numbers.
- Quality
Product quality is of utmost importance. Ensure that the packaging materials you use adhere to the established quality standards while serving the specific needs of consumers.
- Service
Is your packaging materials vendor able to serve you when you decide to downsize or plan an expansion? Assess the ability of the vendor of being flexible to serve your changing requirements.
- Delivery
Though many would recommend that you order enough stock for use when needed, the truth is, it increases your warehouse costs and may cause loss when items are damaged/ expired even before they could be used. Look for a packaging materials supplier with stellar delivery track record.
- Reports
All said and done, the paperwork matters. Clear, easy-to-read documents, reports and accurate invoices are a primary requisite when it comes to a professional business relationship.
- Sustainability
Environment friendliness is worth a check point when you approach a packaging materials vendor as it represents your company's corporate social responsibility.
COMMUNICATION MATTERS
The untold secret to finding the right business deal is clear - transparent communication. You must ask the right questions to be well-informed about your specific requirements. This would enable you select a vendor who is flexible enough to scale up to your expectations with time.
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December 11, 2018
Flexible packaging is being talked about a lot these days, and for good reason. Manufacturers, marketers and even consumers are promoting the use of flexible packaging. The idea of flexible packaging not only serves the mobile consumer's needs but also reduces the environmental impact caused by waste of expired items on the shelves and that results from frequent freight shipments.
SELECTING THE RIGHT FLEXIBLE PACKAGING
Before you investigate the types of flexible packaging materials, it is important to consider the following pointers:
- Type of product
- Product shape, weight and dimensions
- The packaging mechanism
- Handling frequency & exposure to environment
Discuss the above parameters in detail before you move to selecting the right packaging material.
Polyolefin (POF)
This packaging material is versatile, durable and FDA approved. With high level of puncture resistance and seal strength this can be used to pack irregularly shaped items with ease. POF is 100% recyclable which is an added advantage and the POF shrink films offer ultimate clarity to make your product safely packed while being clearly visible. The pre-perforated film variety is often used in the packing of games, toys, foods, books, etc. where visibility is important.
High Density Polyethylene (HDPE)
Also known as polyethylene high-density (PEHD), this is a polyethylene thermoplastic that is made from petroleum and is highly versatile. The packaging material is commonly used for packaging plastic lumber, corrosion-resistant piping, plastic bottles, etc. It is also used in the manufacture of almost anything from hard hats to jugs. The material finds use in heavy-duty Stretch Wrapping needs such as bundling farm produce as it is extremely breathable to be able to maintain the freshness of the products.
Low Density Polyethylene (LDPE)
As the name suggests, LDPE has a lower density. It is highly resistant to moisture, impact and chemicals. Therefore, LDPE is highly used in applications that require heat sealing as well as in the manufacture of wires, cables, flexible lids and bottles.
Linear Low-Density Polyethylene (LLDPE)
The most flexible of the polyethylene films, the LLDPE is very commonly used in the packaging industry. A blended form of LDPE, this material is just perfect for stretching and is commonly used to protect heavy loads during transit.
Polyethylene Terephthalate (PET, PETE)
Clear and tough, the PET possesses good moisture barrier properties. It is globally recognized for its strength, flexibility and 100% recyclability. It takes a new life when recycled. PET is extremely lightweight and is commonly used in plastic beverage bottles for water, soft drinks, and the similar and is a common element found in food jars containing jams, pickles, peanut butter, etc. PET is also safe to use in the manufacture of microwave-safe appliances.
Polypropylene (PP)
Polypropylene is a thermoplastic "addition polymer" with a high melting point that makes it a good choice for hot-fill liquids. PP is a material that is used in the packaging, electrical, automotive and construction industries while also being widely in household applications. It is often used in combination with polyethylene as an outer layer in multi-layer pouches.
Polyvinyl Chloride (PVC, Vinyl)
The flexible and lightweight PVC helps packaging maintain the integrity of products packed within, including medicines. The PVC is largely used in variety of application in construction industries as well as electronics, healthcare, automobile sectors. It is largely used in blister packs, blood bags, cable insulation, etc.
The list is large, and it is wise to use the right flexible packaging material for your products considering whether high melting point, recycling or durability is your primary requirement. It is always better to perform research and multi-layer testing of your packaging to ensure a Packaging that fulfills its purpose well while also appealing consumers' interests.