4 Packaging Tips to Improve Health and Safety

Packaging plays a crucial role in promoting health and safety across various domains, including the workplace, consumer protection, and environmental sustainability. Here’s how effective packaging contributes to health and safety:

1. Protecting Products

Preventing Contamination:

  • Packaging serves as a barrier to contaminants, ensuring that food, pharmaceuticals, and other sensitive products remain safe and uncontaminated during transportation and storage.

Maintaining Integrity:

  • Proper packaging protects products from physical damage, such as breakage, crushing, and moisture, which can compromise product safety and quality.

2. Ensuring Safe Handling and Transportation

Reducing Injury Risk:

  • Ergonomically designed packaging can reduce the risk of injuries to workers by being easier to handle, lift, and transport. This includes using lighter materials, smaller package sizes, and incorporating handles or grips.

Improving Stability:

  • Secure packaging ensures that products are stable and less likely to shift or fall during transportation, reducing the risk of accidents and injuries.

3. Providing Clear Information

Labelling and Instructions:

  • Effective packaging includes clear labels and instructions that inform consumers and workers about how to handle, store, and use the product safely. This can include warnings, usage instructions, and handling precautions.

Compliance with Regulations:

  • Packaging often includes important information required by health and safety regulations, such as expiration dates, batch numbers, and safety symbols, ensuring compliance and consumer safety.

4. Enhancing Workplace Safety

Automated Packaging Solutions:

  • Automation in packaging reduces the need for manual handling of heavy or hazardous materials, thereby minimising the risk of injuries. Automated systems can perform repetitive tasks with precision and consistency.

Safety Features:

  • Modern packaging equipment often comes with built-in safety features such as guards, sensors, and emergency stop buttons, protecting workers from potential hazards.


Packaging is a vital component in the overall health and safety strategy of any organisation. By protecting products, ensuring safe handling and transportation, providing clear information, and enhancing workplace safety, packaging plays an essential role in safeguarding both workers and consumers. Investing in effective packaging solutions not only helps comply with health and safety regulations but also fosters a safer and more efficient working environment.


The Ultimate Guide to Packaging Automation

Introduction to Packaging Automation

In today’s fast-paced, competitive landscape, the ability to streamline processes and enhance efficiency is paramount to success. Packaging automation has emerged as a game-changer, empowering companies to optimise their operations, reduce costs, and stay ahead of the curve.

In this article, we will explore the benefits of packaging automation solutions and the role it plays in streamlining processes. We’ll also delve into the key features of packaging line automation and the common challenges and how to overcome them.

Benefits of Packaging Automation Solutions

Packaging automation offers a multitude of benefits that can revolutionise your business operations. Here are some of the key advantages:

  • Increased Efficiency: Automated packaging systems can streamline your processes, reducing the time and labour required for manual tasks. This translates to higher output, faster turnaround times, and improved overall productivity.
  • Enhanced Accuracy and Consistency: Automated packaging equipment ensures precise and consistent product packaging, minimising errors and waste; this results in a higher-quality output and a more reliable customer experience.
  • Cost Savings: Automation can significantly reduce labour costs, as well as the expenses associated with material wastage and rework. The long-term cost savings can be substantial, positively impacting your bottom line.
  • Improved Safety: Automated packaging systems eliminate the need for manual handling of heavy or hazardous materials, reducing the risk of workplace injuries and enhancing the overall safety of your operations.
  • Scalability and Flexibility: Packaging automation solutions can be easily scaled to accommodate fluctuations in production demands, allowing you to adapt to changing market conditions and customer requirements.
  • Competitive Advantage: By leveraging the power of packaging automation, you can gain a competitive edge in the market, offering faster turnaround times, higher-quality products, and more efficient operations.
The Role of Packaging Automation Equipment in Streamlining Processes

Packaging automation equipment plays a crucial role in streamlining your business processes, the advanced technologies work together to create a seamless and efficient packaging workflow.

Some of the key packaging automation equipment that can help streamline your processes include:

  • Shrink and Film Wrapping Machines: This highly versatile and reliable fully automatic shrink-wrapping machine is suitable for most products including trays, pads, bottles, jars, tins, cartons, bags, pouches and bales. It is built with energy-saving and durability in mind with many features designed in to ensure it runs efficiently and consistently, whatever the application.
  • Labelling Machines: For either apply-only, print & apply and shrink sleeve applications to place information and artwork onto products and outer packaging. Suitable for use as stand-alone machines or networked into existing software systems to automatically capture data.
  • Case Erectors and Sealers: Automated case erectors and sealers streamline the packaging process, ensuring secure and consistent case formation and sealing.
  • Conveyor Systems: Integrated conveyor systems transport products seamlessly through the packaging line, optimising workflow and minimising manual intervention.

By leveraging these advanced packaging automation technologies, you can streamline your processes, improve efficiency, and enhance the overall productivity of your operations.

Choosing the Right Packaging Automation Solutions for Your Business

Selecting the right packaging automation solutions for your business requires a thorough understanding of your specific needs, production requirements, and long-term goals. Here are some key considerations to keep in mind:

  • Scalability and Flexibility: Choose solutions that can adapt to your changing production demands and accommodate future growth without significant modifications.
  • Compatibility and Integration: Ensure the packaging automation equipment can seamlessly integrate with your existing manufacturing systems and enterprise-level software.
  • Efficiency and Productivity: Prioritise solutions that offer the highest levels of efficiency, throughput, and overall productivity to maximise the return on your investment.
  • Reliability and Maintenance: Look for packaging automation equipment with a proven track record of reliability, minimal downtime, and straightforward maintenance requirements.
  • Regulatory Compliance: Ensure the selected solutions comply with industry-specific regulations and standards, such as food safety, labelling, and environmental guidelines.
  • Total Cost of Ownership: Consider not only the initial capital investment but also the long-term operating costs, energy consumption, and maintenance expenses to determine the true total cost of ownership.
Common Challenges in Packaging Automation and How to Overcome Them

While the benefits of packaging automation are well-documented, there are some common challenges that businesses may encounter during the implementation process:

  • Integration and Compatibility: Ensuring seamless integration between the various components of the packaging automation system and your existing manufacturing infrastructure can be a complex task. By collaborating closely with your automation provider comprehensive integration plan that addresses all technical and operational requirements can be developed.
  • Resistance to Change: Employees may be hesitant to adapt to the new automated processes, fearing job loss or the complexity of the new systems. Effective change management, comprehensive training, and clear communication can help ease the transition and foster a culture of acceptance and engagement.
  • Adapting to Changing Requirements: As market demands and customer preferences evolve, your packaging automation solutions must be able to adapt accordingly. Prioritise modularity, scalability, and flexible design in your automation investments to future-proof your operations.
  • Cost Considerations: While packaging automation can deliver significant long-term cost savings, the initial capital investment can be a barrier for some businesses. Carefully evaluate the total cost of ownership, explore financing options, and work closely with your automation provider to identify the most cost-effective solutions.

By acknowledging these challenges and proactively addressing them, you can overcome the obstacles and unlock the full potential of packaging automation, driving sustainable growth and success for your business.

Conclusion: Unlocking Efficiency and Maximizing Productivity with Packaging Automation

By leveraging the benefits of packaging automation solutions, businesses can optimise their operations, reduce costs, and deliver superior products and services to their customers. From increased efficiency and enhanced accuracy to improved safety and greater scalability, the advantages of packaging automation are undeniable.

Together, we can develop a customised automation solution that aligns with your unique requirements and unlocks your full potential. To get started, visit

Automation solutions for small Business

Written by Tony Hacker

Automated packaging solutions are like your own little helpers in the world of small business. They take the hard work out of packaging products, making your life a whole lot easier.

What are Automated Packaging Solutions?

Think of them as your packaging sidekicks. These clever machines are designed to do all the heavy lifting when it comes to packaging your products. Instead of spending hours manually wrapping, sealing, and labelling items, automated packaging solutions can do it all for you in a fraction of the time.

Why are Automated Packaging Solutions Handy for Small Businesses?

Time Saver: Small businesses are often short on time, and every minute counts. Automated packaging solutions help you get more done in less time, freeing you up to focus on other important aspects of running your business.

Consistency: When you’re packaging products by hand, there’s always the risk of human error. Automated packaging solutions ensure consistency in packaging, reducing the chances of mistakes and maintaining a professional image for your brand.

Cost-effective: While the initial investment may seem daunting, automated packaging solutions can actually save you money in the long run. By streamlining your packaging process and reducing the need for manual labour, you can cut down on operational costs and increase efficiency.

Scalability: As your business grows, so does the demand for your products. Automated packaging solutions are scalable, meaning they can adapt to your evolving needs without requiring significant upgrades or changes.

Improved Productivity: With automated packaging solutions, you can package more products in less time, increasing overall productivity. This means you can fulfil orders faster and keep your customers happy.

Professional Presentation: First impressions count, especially in business. Automated packaging solutions can help you achieve a polished and professional look for your products, enhancing their appeal to customers.

Reduced Waste: Manual packaging methods often result in excess packaging materials being used, leading to waste. Automated packaging solutions are designed to optimize material usage, reducing waste and making your business more environmentally friendly.

In a nutshell, automated packaging solutions are a game-changer for small businesses. They save you time, money, and hassle, while also helping you maintain consistency and professionalism in your packaging efforts. So, if you’re looking to streamline your operations and take your business to the next level, investing in automated packaging solutions could be the way to go.

Boosting Investment funds: How Mechanised Arrangements Drive Down Expenses

Written by Tony Hacker

Organisations are continually looking for ways of streamlining productivity and decreasing costs. One progressively famous technique that is reforming businesses is the reception of Automated Packaging Solutions. These modern frameworks offer plenty of advantages, not least of which is their capacity to bring down costs. In this article, we’ll dig into how automation helps reserve costs through decreased labour costs and improved asset use. Besides, we’ll investigate the drawn-out monetary benefits of putting resources into automated packaging frameworks, including further developed return for capital invested.

Lessening Work Costs:

One of the most obvious expense saving advantages of automated packaging is the decrease in labour costs. Customary bundling processes frequently require a critical labour force to deal with errands like arranging, naming, and palletising. In any case, with computerisation, many of these errands can be performed with negligible human mediation, prompting significant reserve funds in labour costs. Via automation, monotonous and work escalated errands can be redistributed to additional essential jobs, further advancing functional productivity.

Upgrading Asset Usage:

Automated Packaging is intended to streamline the utilisation of assets, including materials, energy, and time. Through exact control and observing, these frameworks limit squander and expand asset productivity. For instance, high level bundling apparatus can precisely quantify and administer materials, guaranteeing insignificant wastage and decreasing the requirement for excessive adjust. Moreover, automation empowers better stock administration and time creation, further enhancing asset use and limiting conveying costs.

Limiting Waste:

Waste is a huge wellspring of monetary misfortune for some organisations, especially in the creation and packaging areas. Manual bundling processes are frequently inclined to blunders and shortcomings, prompting more elevated levels of waste and revise. Automated Packaging, then again, offer accuracy and consistency, decreasing the probability of blunders and limiting waste. Whether it’s through exact estimation, precise marking, or proficient palletising, automation assists organisations with limiting waste and decrease pointless expenses.

Long haul Monetary Benefits:

While the forthright interest in automation packaging might appear to be significant, the drawn-out monetary benefits far offset the underlying expenses. With less work costs, streamlined asset usage organisations can accomplish a better yield on venture (return for capital invested) from their automated packaging. Besides, upgraded functional proficiency empowers organisations to offer more cutthroat evaluating, drawing in clients and acquiring a more grounded traction on the lookout.


Automated packaging offers a bunch of cost-saving advantages that are fundamental for organisations hoping to flourish in the present cutthroat scene. By diminishing work costs, upgrading asset usage, and limiting waste, automation drives down costs providing an overwhelming benefit. Besides, the drawn-out monetary benefits of putting resources into automated packaging, including further developed return on initial capital investment makes them an essential speculation for organisations hoping to get their future achievement. As innovation keeps on propelling, the job of mechanisation in bringing down expenses and driving proficiency will become more articulated, making it a basic part of any cutting-edge creation activity.

The Process Of Automating Your Packaging – Which Key Steps Are Involved?

Written by Tony Hacker

The idea of automating packaging can seem daunting at first, however by taking the right steps and seeking the right support, it doesn’t need to be. With the clear benefits that automated packaging solutions offer, it’s important for your business to consider which opportunities there are for improving your production lines. In this article, we’ll break down the key steps involved in the process to provide you with clarity and a path towards process optimisation.


Assessing & Getting a True Understanding of Your Current Systems

The first step in automating your packaging process is to assess your current systems thoroughly. This involves identifying pain points, bottlenecks, and areas for improvement. Understanding the intricacies of your existing packaging process is crucial for designing a tailored automation solution that addresses specific needs and challenges within the business, whilst avoiding exacerbating underlying problems that you may otherwise not have discovered.

The support of an automation expert here can ensure that you are looking for the right markers and in turn help you to build a strong foundation for the rest of the process.


Customisation and Ensuring That The Right Areas Are Automated For Your Business

Automation is not a one-size-fits-all solution, and there are many possibilities that might not even suit your business’s structure. It’s therefore essential to ensure that the automation technology you choose aligns with your business goals, objectives, and underlying needs. Taking the time to work with somebody who can align your packaging systems with the rest of your business allows you to automate the right tasks that will have the most impact, whether it’s:

  • Primary packaging
  • Secondary packaging
  • Labelling
  • Palletising
  • Quality control


Equipment Selection

As you might expect, there’s a huge variety of automation machinery to choose from when it comes to packaging. Selecting equipment that integrates seamlessly with your existing systems and meets your production requirements is key to a successful automation implementation. It’s important to remember that only once you have audited your existing packaging lines can you understand which equipment is going to support your needs moving forwards.

Some examples of packaging equipment include:

  • Robotic palletisers
  • Automated case packers
  • Box machines
  • Labelling machines
  • Filling machines

Preparing Your Site For Change

Preparing your site for automation involves assessing space requirements, making necessary infrastructure upgrades, and ensuring compliance with safety regulations. This step creates a conducive environment for the installation and operation of automated packaging equipment, and planning ahead of time allows this to be a smooth transition within your operations.


Implementation & Installation

Once the groundwork has been laid, it’s time for implementation and installation. This stage involves installing the selected automation equipment, integrating it with your existing systems, and conducting thorough testing to ensure everything operates smoothly. Whilst there can be a number of moving parts to this stage, utilising the right expertise removes the headache and simplifies the process for your business.



Proper training is crucial for ensuring the successful adoption of automation technology. Training your staff on how to operate and maintain the automated packaging equipment is essential for maximising efficiency and productivity on a consistent basis. As with anything new, providing people with the opportunity to become familiar with new systems is an effective way to ensure the business truly gets the most out of them.


Preventative Maintenance

Regular maintenance is fundamental to keeping your automation equipment running smoothly and minimising downtime. One advantage of automation systems is that preventative maintenance technology can be used to help identify and address potential issues before they escalate, ensuring continuous operation and maximum uptime. The ongoing maintenance and optimisation of your equipment should always be factored into every stage.


Start Taking Advantage Of Better Efficiency With Your New Systems

Once the necessary packaging processes have been automated, you can start reaping the benefits of improved efficiency and productivity. Automated packaging systems allow for faster production speeds, reduced errors, and enhanced quality control, ultimately leading to cost savings and increased competitiveness in the market.


Automating your packaging process can be a game-changer for food manufacturers looking to stay ahead in today’s competitive market. By following the key steps outlined in this article, you can streamline your operations, improve efficiency, and achieve greater success. If you’re ready to take the next step towards automation, we invite you to book a free appointment to discuss your automation needs and explore how we can help transform your packaging process. Don’t let complexity hold you back – embrace automation and unlock your full potential today.

Food Manufacturing In 2024 – Raising The Bar

Written by Tony Hacker

The food manufacturing industry here in the UK is extremely competitive, and staying ahead of the curve is not just a strategy but a necessity. As we move into 2024, the landscape is still evolving at an unprecedented rate, and businesses need to rethink their approach towards every aspect of the production process.

As mentioned in a recent article, packaging is a stage that can often be overlooked, despite it holding a number of opportunities for the improvement of your business. So in today’s article, we’ll delve deeper into the transformative power of packaging automation, relating specifically to food manufacturers who are not only looking to keep up with the growing industry, but who aim to increase their market share and outpace competition in the near future.


Why Does The Bar Need To Be Raised?

Not only does your business need to continue generating a healthy profit, it also faces constant challenges that could seriously impact your ability to stay afloat. Whilst there’s obviously a broad spectrum of considerations that need to be made, here are a few that will take centre stage in 2024 and the next 5-10 years:


  • Food hygiene – there is relentless pressure on food manufacturers to provide safe products that withstand the wear and tear of transportation and supermarket shelves. At a time where food health regulations continue to get stricter, ensuring the quality and longevity of your food product is so important.


  • A growing population – the UK population alone is projected to grow by more than 2.1 million in the next 10 years, leaving food manufacturers with increasing demand. That’s all well and good if the business can handle it, but failing to keep up or to maintain quality could see you suffocated by competitors.


  • Increasing costs – you don’t need us to say it, but costs are increasing everywhere you look. Costs for ingredients, costs for staff, costs for energy, costs for materials – it’s all going up and it doesn’t want to stop. It’s crucial to your success as a business that when and where you can, costs are cut.


Involving Packaging Automation At The Right Time

The key to all of these issues lies in utilising packaging automation at the right time, which we’ve seen have profound impacts on the costs of businesses and their ability to increase output without losing quality.


Uncompromised Food Hygiene

Packaging plays a pivotal role in ensuring the quality and longevity of food items, especially during transportation and shelf life. Often, it’s external influences that sees food items go to waste – whether it’s something getting into the product that shouldn’t, or damage to the product that makes it unsellable.

By embracing packaging automation early in your processes and taking advantage of the deep knowledge and insight that automation experts can provide, you not only meet regulatory standards but also elevate the hygiene and safety profile of your products. Automation ensures consistency and precision, reducing the risk of damage and contamination and safeguarding your brand’s reputation.


Meeting the Demands of a Growing Population

Keeping up with escalating demand can be a tricky challenge, but it doesn’t need to be. Plus, as mentioned above, succeeding to do so establishes you as a leader in a competitive market.

Packaging automation allows for scalable and efficient processes, ensuring that your production line is equipped to handle increased demands seamlessly. Proactive technology can even help you to manage any seasonal changes quickly without wasting costs on unnecessary output. By automating packaging, you not only maintain product quality regardless of increases in output, but also position your business to thrive amidst intensifying competition.


Mitigating the Impact of Rising Costs

The relentless rise in costs across numerous elements of production poses a significant threat to your business’s profitability. In such a climate, cost-cutting becomes a crucial aspect of sustaining success. This is where manual packaging systems can create serious issues, preventing the business from scaling effectively.

Involving packaging automation experts as early as possible in your process enables your business to take advantage of important technologies that prove instrumental in reducing labour costs, minimising material wastage, and optimising your resources. By implementing automation solutions, you are able to enhance operational efficiency and create an effective buffer against the financial strains posed by increasing costs.


In the face of evolving challenges like stringent food hygiene regulations, a growing population, and escalating costs, food manufacturers need proactive strategies in order to survive. Packaging automation is a powerful tool, addressing these issues head-on. Early involvement of packaging automation and collaboration with packaging experts position your business to raise the bar and set the standard in the competitive UK market.

Hidden Packaging Opportunities That Are More Achievable That You Might Think

Written by Tony Hacker

Competition, increasing costs, and fluctuating demand create the need to optimise profits across the business and take advantage of innovative solutions that streamline operations and continue to allow for growth. One area that often goes overlooked is packaging automation. By leveraging advanced technologies and automated processes, manufacturers can unlock a number of hidden opportunities that can revolutionise the whole business.

In this comprehensive guide, we will explore the vast potential of packaging automation and how it can transform manufacturing operations in ways you may not have considered before.


The Power of Packaging Automation

Packaging automation involves the integration of advanced technologies such as robotics, artificial intelligence, and predictive maintenance to improve efficiency, accuracy, and speed throughout your processes. By automating packaging processes, manufacturers can achieve significant advantages that go beyond traditional manual methods. Let’s take a look at some of the hidden opportunities that packaging automation presents for manufacturers.


Achieving Seamless Maintenance with Predictive Technology

One of the key advantages of packaging automation is the ability to achieve a seamless maintenance strategy, through the implementation of predictive technology. Predictive maintenance utilises data analytics and machine learning algorithms to predict and prevent equipment failures before they even occur.

By continuously monitoring machine performance and analysing data in real-time, manufacturers can proactively identify potential issues and schedule maintenance activities to avoid costly downtime. This not only improves overall equipment effectiveness but also extends the lifespan of packaging machinery, resulting in substantial cost savings.


Near Zero Waste

Sustainability has become a top priority for many consumers, and as such, many manufacturers across all industries. Packaging automation plays a crucial role in helping businesses achieve their sustainability goals by minimising waste.

These automated systems are designed to optimise material usage, reduce packaging waste, and ensure precise packaging measurements. By eliminating human error and optimising every step of the packaging process, manufacturers can significantly reduce the amount of waste generated during production. This not only benefits the environment but also improves operational efficiency and cost-effectiveness.


Improved Inventory Management With Demand Forecasting

Accurate demand forecasting is vital for efficient inventory management. Packaging automation enables manufacturers to gather and analyse real-time data on consumer demand, market trends, and production capacity. By leveraging this data, manufacturers can make informed decisions and optimise inventory levels ahead of time.

Being able to respond swiftly to changes in demand enables businesses to reduce excess inventory and avoid stockouts, improving customer satisfaction, reducing carrying costs, and resulting in enhanced profitability.


Up To 600% More Output

Automation has the potential to revolutionise productivity in manufacturing and improve output more than many businesses might think. By implementing the right packaging automation, manufacturers can achieve remarkable increases in output; according to research, automated packaging systems can deliver up to 600% more output compared to manual processes.

Automated machines can operate at high speeds without compromising on quality, allowing manufacturers to meet growing demands and scale production capabilities. Increased productivity translates to higher profitability and a competitive edge in the market.

Becoming a Sustainable Organisation

Sustainability is not just about minimising waste; it’s about adopting a holistic approach to environmental protection. Packaging automation enables manufacturers to become more sustainable organisations by reducing their carbon footprint, conserving energy, and optimising resource usage.

Automated packaging systems can be designed to minimise energy consumption, utilise eco-friendly materials, and optimise packaging designs for more efficient transportation. By embracing sustainable practices, manufacturers can enhance their brand image, attract environmentally conscious customers, and contribute to a greener future.


Maximising Profit Margins Thanks To Optimised Cost-Effectiveness

Packaging automation offers manufacturers the opportunity to maximise profit margins by improving cost-effectiveness throughout the manufacturing process. Automated packaging systems reduce labour costs, which can account for up to 60% of packaging costs, by minimising the need for manual intervention.

Additionally, automation optimises packaging material usage, reducing waste and material costs. By streamlining packaging processes, manufacturers can achieve higher operational efficiency, reduce overhead expenses, and improve their bottom line. Maximising profit margins allows manufacturers to invest in research and development, innovation, and business growth for the long term. With an average ROI of around 9 months, packaging automation machines quickly become a profitable investment.


Packaging Automation

If you’re ready to explore the potential of packaging automation for your business, you can see how we help to uncover cost-saving opportunities here. Our experts can support you at any stage of the packaging automation process, whether you require a systems audit, advice, or supply and tailored setup.

Packaging Solutions That Scale Your Business – Insight From An Expert

Written by Tony Hacker

In the ever-changing landscape of modern business, packaging isn’t just about enclosing a product. It’s a strategic tool that can shape your brand identity, influence customer perceptions, and drive growth. As a packaging specialist for more than a decade, I’ve witnessed first-hand how businesses can transform their operations by adopting the right packaging solutions that are best suited to their product and process.


The Role Packaging Plays In The Growth Of Manufacturing Businesses

Your product is not just what’s inside the box; it’s the entire package. Effective packaging goes beyond protecting your goods – it communicates your brand message and establishes a connection with your customers. The first touchpoint with consumers often occurs through your packaging, making it crucial in shaping the customer experience.

A thoughtful packaging system sets the stage for continuous business scalability not only as a result of this improved customer perception that leads to higher lifetime value, but also thanks to its ability to streamline profit margins.


Challenges With Traditional Packaging

Traditional packaging methods come with their set of challenges. Manual processes prone to human error can lead to inconsistencies and quality issues. What’s more is that, as businesses grow, the limitations of scalability become apparent, hindering efficiency and increasing operational costs.

The more your packaging systems rely on manual processes, the more complexity is involved with changing or growing the system in future, which often prevents swift adaptation to new standards, requirements, or designs. This inability is what leads to difficulties in developing your product and increasing your output as your business grows.


An Expert’s Perspective On Packaging Automation

Now let’s take a look into the most important tool for creating a packaging process that doesn’t face these issues – automation. Having worked with many large manufacturers across the UK, I’ve witnessed the transformative power of automation in addressing the shortcomings of traditional packaging. Automation isn’t just a buzzword; it’s a strategic approach that can revolutionise your operations.

From reducing errors to ensuring consistent quality and output, packaging automation is a game-changer for businesses aiming to scale effectively, providing you with:

  • Precision and consistency that eliminates much of the human error that often holds systems back.
  • Cost-efficiency thanks to significant waste reductions and reduced labour costs.
  • Improved output that not only minimises delays but enhances the quality of your packaging and overall product.
  • Adaptability that lends itself to developing larger-scale systems and better packaging design for your products.


Implementing the right packaging solutions can be a catalyst for your business’s growth. As we’ve seen, packaging isn’t simply a means to an end; it’s a powerful tool that can drive brand success. By understanding the importance of packaging in business growth, acknowledging the challenges of traditional methods, and embracing the modern perspective on packaging automation, you can position your business for sustained success.

If you’re ready to explore packaging solutions tailored to your business needs, I invite you to connect with me on LinkedIn here, where I’ll continue to share free information and tips on optimising your packaging processes, enhancing your brand, and building a system for long-term success.

Frontline Packaging designs and manufactures new case packing machine

Frontline Packaging Limited has recently completed the installation and commissioning of a major, innovative new packaging line for ethical, fair-trade tea producer Clipper Teas. Tony Hacker, MD at Frontline Packaging explains why this is an exciting project for the business. “It’s a first for Frontline Packaging in many ways and represents the development of the business into the design and manufacture of a new case packing machine, as well as the supply of complete end-of-line packaging systems. We’re very happy with the way it went, we handled the whole project in-house and it has worked extremely well since the day it was commissioned.”

Boosting tag and bag tea production capacity

Due to an increase in business, particularly from the export market, Clipper needed to increase their production capacity for string & tag tea. This led to the purchase of an additional tea machine to manufacture the tea bags which in turn created the need for a whole new packaging line to pack the tea cartons in to perforated shelf-ready cases. The line needed to produce and pack a wide selection of case collations including cartons containing many different flavours.

It was a complex project and Clipper chose Frontline Packaging Ltd because it displayed a clear understanding of the brief and had performed well when it previously supplied and installed four automatic shrink-wrapping systems and a pallet stretch wrapper. Frontline initially surveyed the application and proposed a complete solution for packing the tea cartons from the point where they exit from the tea bag making machine.

Designing the system

Frontline designed and manufactured the case packer and conveyors and supplied a carton closer, case erector, case sealer and print & apply labeller. It then installed and commissioned the complete system and co-ordinated the whole project through in-house project management. It also worked closely with Clipper to ensure the design of the cases worked efficiently within the new system.

There were a number of specific technical challenges that had to be overcome with this project, and this is where Frontline was able to add value with its knowledge and experience of end-of-line packaging and specifically case-packing applications.

Technical challenges

The main challenge was to place the rectangular cartons into the case without clashing with the open case flaps. A Universal Robot supplied by R.A. Rodriguez was chosen for this part of the task because it allowed Frontline to tilt the collations of cartons to deflect the top flaps of the case and therefore avoid any clash.

Another key challenge was to orientate the cartons into the right position for packing, which required three ninety-degree rotations as they travel through the system. Each rotation had to be consistent and reliable to ensure the cartons were delivered in the correct orientation to the next stage of the process.

At the heart of the system is the case packer and the collaborative Universal Robot was key to its design. It was chosen because it works well in a more compact machine. It is specifically designed to allow enhanced and safe human/robot collaborative working – making it easier and safer to use in areas with limited space. It also has a very easy to understand, intuitive touch-pad control system, which allows the customer to easily modify or create programmes.

The combination of these features allowed the machine to fit into the limited space available and to be adapted easily to the varied nature of the application.

The shelf-ready cases posed another challenge. They are particularly long and narrow which makes them difficult to erect, load and seal. A key factor in over-coming this was Frontline’s contribution to the design of the cases and to various features that were incorporated into each machine within the system.

Delivered and working within a week

Steve Norris, Engineering Manager at Clipper Teas, is very happy with how the project went. ” The fact that Frontline had control over the whole of the packaging project is the main reason that it worked so well and was up and running so quickly. This allowed us to concentrate on the tea bag production side of the project, safe in the knowledge that Frontline was taking care of the down-stream equipment. We’re extremely pleased with the system and it’s performing really well and we were particularly impressed that it was up and running so soon after delivery.”

“Another benefit of having Frontline control the whole project was the speed of delivery and commissioning. Delivery of the equipment took place on a Saturday, it was moved into place on Sunday and it was running by Wednesday, followed by commissioning and training being completed on Friday. Since then the system has been extremely reliable and we have already proved its versatility by adding a new format that was not part of the original design brief.”

The success of the project marks another significant milestone for Frontline since its formation in 2012, which now operators from new premises near Cambridge, by showing that it can handle the design and manufacture of its own case packing machines as well as project management of complete systems. This also complements its on-going activities of supplying and supporting a highly regarded product range including case erectors, sealers, shrink wrappers and pallet wrappers.

Frontline Packaging Impresses Customer with Synthesi Pallet Wrapper

A top quality manufacturer of own label breadings, coatings, marinades and powder sauces for the fast food service industry has recently placed an order for  its first turntable pallet stretch wrapper from Frontline Packaging Limited. It was a welcome development for the customer as they were wrapping pallets by hand. As production capacity increased it needed to speed up its pallet wrapping operation and make it more efficient and effective.

Having identified the need to automate its pallet wrapping operation, the customer approached Frontline Packaging for some help choosing the right machine. “Frontline were very helpful and came along to survey the factory and help us work out what we would need to fit in to the current operation,” he explained. “They showed us the Atlanta Synthesi machine which seemed ideal, and we kept it on loan for a week to make sure we were happy with it.”

The customer needed a machine that was compact, easy to install and simple to operate in limited space in the factory. The Synthesi worked really well during the loan period and the customer loved it. “The Synthesi is perfect for those customers taking a first step in to automating their pallet wrapping,” says Tony Hacker, MD of Frontline Packaging. “It’s incredibly well-designed and robust and very straightforward to use. It’s also extremely good value for money and was the perfect solution for this customer to speed up its pallet wrapping operation.”

The customer quickly ordered the machine and it has been working non-stop ever since.