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As production demands rise and labor shortages persist, manufacturers are rethinking how they package and prepare goods for shipment as part of broader manufacturing automation efforts. Manual processes that once worked are now slowing operations and impacting consistency.
Enter automated packaging systems - smart, scalable solutions that transform end-of-line operations. In this blog, we'll break down key components of packaging automation, the benefits of custom engineering, and how Nevatio helps manufacturers stay ahead with tailored solutions.
Packaging automation refers to the use of machines and control systems to handle various packaging tasks with minimal human involvement. These automated packaging systems are designed to prepare products for shipment quickly and accurately, reducing the need for manual labor while improving consistency and productivity across the board.
For modern manufacturers, packaging automation ensures that each product is sealed, labeled, and prepared for transport with precision. By automating repetitive tasks, businesses can reduce errors, maintain quality standards, and keep up with high-volume demands without overburdening their workforce.
An effective automated packaging machine setup can include several key components depending on your product type, packaging material, and distribution strategy.
Below are common types of automated packaging equipment that streamline end-of-line operations:
Cartoners are machines designed to automatically erect, fill, and close cartons. These systems handle everything from folding flat blanks into boxes to inserting products and sealing them shut.
Benefit: Streamlines box assembly and product insertion into a single process, reducing manual labor and improving throughput with consistent packaging accuracy.
These machines group multiple products (such as bottles, pouches, or cartons) into cases and seal them for shipping. Variants include wraparound case packers, drop packers, and side-load systems.
Benefit: Ideal for high-volume operations, case packers and sealers increase packing speed and enhance product protection for bulk shipment, reducing the risk of damage in transit.
Robotic palletizers automate the stacking of packed boxes onto pallets with speed and precision. These systems can be programmed for multiple product types and stacking patterns.
Benefit: Eliminates the need for manual pallet loading, which reduces ergonomic strain, increases efficiency, and ensures consistent stacking for transport and storage.
While off-the-shelf machines may fit general applications, they rarely address the nuanced needs of a specific production line. That’s where custom automated manufacturing systems come into play.
Tailored packaging automation provides a better return on investment by adapting to existing workflows, optimizing space constraints, and accommodating product-specific variables. Companies seeking a more flexible and scalable approach often turn to manufacturing automation and process optimization through retrofits rather than full system replacements.
At Nevatio, we specialize in retrofitting outdated or underperforming lines with smarter, more efficient packaging automation technology. Our team designs solutions that enhance what manufacturers already have, making the transition to automation cost-effective and minimally disruptive.
Recognizing the right time to automate can have a major impact on your bottom line. In the automation manufacturing industry, the following scenarios often indicate it's time to upgrade your packaging operations:
Rising labor costs that eat into profitability
Inconsistent product packaging that leads to returns or customer dissatisfaction
Production bottlenecks caused by manual slowdowns or shift limitations
Growth or scale-up needs that require faster throughput and flexibility
Industries that benefit most from packaging automation include food and beverage, consumer goods, pharmaceuticals, electronics, and industrial manufacturing - particularly when packaging precision, speed, and reliability are top priorities. For companies seeking to streamline distribution and reduce warehousing inefficiencies, packaging automation also serves as a vital component of supply chain automation initiatives.
In operations with high volumes of corrugated packaging, the addition of a cardboard baler can further streamline material handling and support sustainability goals as part of a comprehensive packaging automation strategy.
Nevatio provides comprehensive automation engineering services designed to meet today’s packaging challenges head-on. Our approach combines mechanical machine design, electrical engineering, and software integration to create end-to-end solutions that deliver long-term value.
We specialize in deploying and retrofitting automated equipment that integrates seamlessly with upstream and downstream systems - minimizing downtime and maximizing productivity. As a FANUC authorized system integrator, we have deep expertise in deploying FANUC robotics for complex tasks, from robotic palletizing to high-speed material handling.
Whether you need a FANUC integrator for a single cell or a complete fanuc robotics integrator for a facility-wide project, our team brings the experience, tools, and precision needed to ensure your automation solution delivers results.
Nevatio Engineering is an agile design and engineering consulting team capable of on-demand mechanical and electrical engineering, functional prototyping, engineering documentation, and machine retrofits. Our added knowledge in industry design standards such as ASME, ANSI, ISO, NFPA, NEC and BS allows us to quickly integrate our services with your existing standard design processes, keeping your resources free from unnecessary rework.
We specialize in helping industry leaders solve difficult engineering and design problems. Our mission is to empower our clients with the tools and skills necessary to create solutions to their technical problems. With our expertise, clients can address any technical design problems that stand in their way.