Choosing a complete packaging line or building your own? A practical step-by-step guide

A packaging line is often a major investment. Whether you pack vegetables, fruit, or other agricultural products, the right combination of machines determines the efficiency, capacity, and reliability of your packaging process.

When purchasing a packaging line, you can choose between a complete existing line or a line you assemble yourself from various machines. But how do you determine which solution is most suitable for you?

To support you in this, we have developed the step-by-step plan below. This allows you to map out your requirements and select the right machines for your packaging line. The step-by-step plan is also available as a handy PDF flowchart! 

👉Download the packaging line step-by-step plan as PDF

Step 1: Determine the Product and Packaging

The starting point of every packaging line is the product that needs to be packaged.

You then determine how the product should be packaged. Common packaging types include:

• Net packaging
• Flow pack
• Top seal
• Shrink film
• Cardboard tray
• Other consumer or bulk packaging

It is also important to determine:

• Is one product or multiple products packaged per unit?
• Is packaging based on weight or a fixed number of units?
• What dimensions and weights will the packages have?

These starting points form the basis for choosing the packaging machine and the other components of the line.

Step 2: Choose Between a Complete Line or Building Your Own

When purchasing a packaging line, there are two options:

1. Choosing a complete existing packaging line

The advantage of a complete line is that all machines have previously worked together. As a result, it is often known what capacity can be achieved and how the machines connect to one another.

The disadvantage is that it can be difficult to find a used line that fully matches your specific requirements and product characteristics.

2. Building your own packaging line

The alternative is to assemble a packaging line yourself.

The main advantage of this is flexibility. You can select machines that perfectly match:

• The desired capacity,
• Specific product characteristics,
• Available space,
• Desired functions and options,
• Local service and support from manufacturers.

Additionally, you avoid investing in machines or components you do not need.

Step 3: Select the Right Packaging Machine

The packaging machine itself often forms the heart of the packaging line.

Many packaging machines can process various products. However, it is important to carefully assess whether a machine is optimally suited for your specific application. A versatile machine sometimes requires compromises in terms of capacity, accuracy, or ease of use. Where possible, you should ideally choose a machine developed specifically for your product.

Therefore, pay attention to the following, among other things:

• Capacity per hour,
• Suitability for printed film,
• Labelling options,
• Printing of date codes or lot numbers,
• Flexibility for different packaging formats.

Step 4: Determine How the Product is Fed

Before a product can be packaged, it must arrive at the packaging machine in the correct manner.

The feed can come from, for example:

• Another processing machine,
• A dosing hopper,
• Bulk bins,
• Boxes or crates,
• Conveyor belts.

The chosen feed method affects the capacity and layout of the entire line.

Step 5: Consider Inspection and Quality Control

For many products, an inspection step is desired before they are packaged.

Depending on the product, you can choose from:

• A flat inspection belt,
• A roller inspection belt,
• A optische sorteerder.

This allows defective products, damage, or quality differences to be removed in time.

Step 6: Choose the Right Weighing Solution

Accurate weighing is essential for an efficient packaging process.

When choosing a weighing system, the following questions are important:

• What is the desired packaging weight?
• How accurately must the weighing be performed?
• What capacity is required?
• Does the capacity match that of the packaging machine?

For some products, such as vine tomatoes, strawberries, and pointed peppers, manual weighing is still commonly used. For this purpose, special weighing lines with multiple workstations and integrated weighing tables are available.

Step 7: Add the Required Additional Components

Depending on the packaging process, additional machines may be required.

Common additions are:

Step 8: Check the Key Points of Attention

Before making a final decision, it is advisable to critically assess the complete line one more time.

• Line capacity

The machine with the lowest capacity ultimately determines the capacity of the entire packaging line. Therefore, ensure that the capacities of all machines are well aligned and that the lowest capacity matches your desired final capacity. 

• Communication between machines

Some machines need to exchange data with each other. Think, for example, of the communication between a weigher and a packaging machine.

The emergency stop circuit must also be correctly integrated within the entire line.

• Service and support

A packaging line often consists of machines from multiple manufacturers. Therefore, check in advance whether sufficient local service and technical support is available, in case you need it in the future.

• Available space

Not every packaging facility offers sufficient physical space for an extensive line. Therefore, make a proper layout of the available space in advance.

• Connections

Check whether the necessary provisions are in place, such as:

• Electrical connections,
• Compressed air provisions,
• Any additional utility provisions.

A Packaging Line Starts with a Good Plan

Whether you opt for a complete used packaging line or a custom-assembled solution, good preparation prevents costly adjustments later on.

By first mapping out the product, packaging, desired capacity, and available space, it becomes easier to select the right machines and assemble a packaging line that performs reliably for years.

Still unsure about buying or assembling your packaging line? Please feel free to contact us, so that one of our specialists can think along with you and find the best solution together.