Packaging Equipment Lifecycle Management: Maximizing ROI Through Preventive Maintenance

Many manufacturers think they can't do anything about this problem — all they can do is conduct maintenance as quickly as possible to minimize the damage. However, this approach isn't the only option, nor does it decrease costs. It actually increases the packaging equipment's total cost of ownership (TCO).

Rather than reacting, manufacturers need to be proactive when it comes to packaging equipment maintenance. Your company can do this with a combination of lifecycle management and preventive maintenance. Together, these approaches extend packaging equipment lifespans and decrease their TCO. They also make your operations more reliable, which is vital for your company's reputation and connection with its business partners.

The Four Pillars of the Packaging Equipment Lifecycle

While packaging equipment lifecycle management strategies vary, they tend to consist of four main phases:

1. Acquisition and Commissioning

In this phase, equipment is purchased and connected to the existing manufacturing process. The equipment you choose here has an enormous impact on lifespan, TCO and your overall return on investment (ROI). While purchasing equipment with a low up-front price may seem like a smart move, these pieces of equipment often require more maintenance and need to be replaced sooner than models with a higher up-front cost.

2. Utilization and Operation

Once the equipment has been integrated safely, it can start playing its part in daily production runs. In this phase, lifecycle management is about how operators interact with the equipment. Each operator needs to be trained in the standard operating procedures for the equipment they use. Proper training prevents abuse and premature wear, extending the lifespan of each piece of equipment and minimizing unnecessary downtime.

3. Maintenance and Optimization

Even when your team follows standard operating procedures, machines still require maintenance, and you can optimize the equipment's performance for your system. Schedule regular maintenance in advance for each piece of packaging equipment to prevent damage and unexpected downtime. You can also use the data on the equipment's performance so far to identify inefficiencies and make operations smoother.

4. Decommissioning and Replacement

Eventually, packaging equipment will wear down. During this process, the equipment will reach a tipping point where the cost of maintenance exceeds the value of replacing it. You can use data-driven analytics to identify this point exactly, saving your company as much money as possible. Then, you can decommission and replace the old equipment, restarting the lifecycle all over again.

Best Practices for the Packaging Equipment Lifecycle

Lifecycle management is all about small practices that compound over time. When your company treats its equipment well in the short term, you'll see extensive benefits in the long term.

Four of the best practices for your packaging equipment are:

1. Standardized Daily Inspections

Maintaining your equipment's health is a team effort. It's not just the maintenance team's job. Operators and managers should also make it a priority, and standardized daily inspections are a great place to start. Before turning on the equipment, operators should look for any signs of debris or damage to the equipment. During operation, they should also listen closely for any auditory anomalies, like grinding or shrieking. These practices can help your company detect issues well before they become a problem.

2. A Strategic Spare Parts Inventory

Some packaging components suffer more wear than others. Belts, sealing bands and cutting blades need to be replaced far more often than control panel buttons, for instance. Keeping these parts on hand eliminates lead-time delays if an unexpected failure occurs. Your maintenance team can then begin repairs immediately, getting the equipment up and running again as fast as possible.

3. Environment Control

Dust, humidity and extreme temperatures can have a profound impact on your equipment's health. They can easily disrupt electronic components, warp parts and make equipment less efficient overall. Periodic cleanings and climate-controlled workspaces can mitigate these issues, as can keeping all equipment within safe operating temperatures. These practices extend equipment lifespans and create safer operating conditions for everyone.

4. Software and Firmware Updates

Most modern packaging equipment comes with digital interfaces and mechanisms. These systems may need periodic software and firmware updates to prevent bugs and optimize efficiency. If any such updates come across your desk, be sure to approve them to keep digital equipment up to date.

How to Reduce Packaging Equipment Downtime Through Maintenance

Preventive maintenance is one of the best ways to minimize unexpected downtime and extend the lifespan of your equipment.

The first step you take in your preventive maintenance journey should be scheduling planned downtime in advance. Machines can't run forever, no matter how high-tech they are, so some downtime is unavoidable. Planning that downtime in advance gives your company control over when it happens, allowing you to plan around it so that it doesn't impede production.

Your maintenance team can then use this time to assess the equipment's health, address any pressing issues and identify areas of concern. They can also lubricate components that experience a lot of friction and calibrate sensors to keep equipment operating effectively.

Conduct a vibration analysis and thermal analysis to detect early warning signs, like bearing vibrations and motor overheating. You can also run a root cause analysis if a particular piece of equipment failed during daily operation. This process helps the maintenance team identify the source of the problem so it doesn't become a repeat issue.

Benefits of Preventive Maintenance for Packaging Equipment

Embracing preventive maintenance can have many benefits for your packaging equipment, including:

Reduced expenses: The cost savings with packaging equipment preventive maintenance are the main appeal. The reactive approach to maintenance brings with it overtime labor rates, expedited shipping fees and missed production quotas. Preventive maintenance avoids all of these while making outright breakdowns far less common, turning unexpected and costly failure into predictable and inexpensive tuneups.

Energy efficiency gains: Well-maintained packaging equipment consumes less power overall because the machine doesn't have to work harder than necessary to maintain the desired output. This increased efficiency can lower your company's utility bills and make production runs more consistent.

Resale value retention: If your company keeps comprehensive maintenance logs for its equipment, each piece's resale value will be much higher at the end of its lifecycle. Proof of preventive maintenance shows prospective buyers that the equipment has been cared for and gives them a strong sense of its current condition.

Partner With Neway Packaging for All Your Preventive Maintenance Needs

At Neway Packaging, we understand how important packaging equipment is to your company. It's the backbone of your production processes and helps you serve your customers every day. To do that, though, you need the best equipment, and you need to keep it running safely. Neway Packaging can help with both. We offer a wide array of packaging equipment and automation, as well as a robust preventive maintenance program. That way, your company can focus on what matters most.

Fill out our contact form or call 310-898-3400 to learn more!