This article will take an in-depth look at packaging equipment.
What will be covered will include:
Common packaging machinery includes filling systems, baggers, form-fill-seal equipment, shrink wrapping and stretch wrapping machines, case packers, carton sealers, palletizers, and labeling, coding, and marking systems. Most packaging lines use multiple machine types working together to move products from infeed through sealing, inspection, and shipment preparation.
Packaging automation increases throughput, improves consistency, and reduces labor requirements by standardizing repetitive tasks such as feeding, sealing, wrapping, case packing, and labeling. Automated packaging equipment also supports better quality control through repeatable settings and integrated sensors, while robotics and programmable logic controllers can coordinate complex packaging lines at higher speeds.
Key factors include product size and fragility, target package style, required seal strength, labeling and coding needs, production rate, changeover frequency, available floor space, and operator skill level. It is also important to consider maintenance access, spare parts availability, training requirements, and whether the equipment must integrate with conveyors or existing packaging line controls.
Packaging machinery cost is typically evaluated using both the initial purchase price and the total cost of ownership over time. Ownership costs may include energy consumption, preventive maintenance, downtime risk, consumables such as film and adhesives, operator labor, and changeover time. Calculating material usage and cost per package is a practical way to estimate ongoing spend and compare equipment options.
Packaging equipment is used across food and beverage, pharmaceuticals, cosmetics, industrial products, chemicals, and consumer goods. Benefits include faster packaging speeds, reduced manual handling, improved package consistency, better product protection during shipping and storage, and easier compliance with traceability requirements through labeling and coding.
Supplier proximity can be helpful for service response time, training, and access to technicians, especially for high-throughput packaging lines where downtime is costly. However, remote support, spare parts programs, and clearly defined service agreements can be equally important when evaluating vendors, particularly for specialized packaging machinery.
This section will explore the various kinds of packaging machinery and equipment that are utilized in modern manufacturing and distribution facilities. Selecting the right packaging equipment is essential for optimizing packaging lines, improving efficiency, ensuring product safety, and meeting industry-specific regulatory standards. Understanding each type of packaging machinery helps businesses identify the solutions that best match their production requirements, packaging material preferences, and end-use applications.
The different types of packaging machinery are crucial components in automated packaging systems. They streamline the packing process, enhance productivity, reduce labor costs, and promote quality assurance across a variety of industries. Below are the principal categories of packaging machines:
Filling machines or liquid fillers represent one of the most common packaging machines. They are utilized for packaging diverse products—primarily in beverage, food, pharmaceutical, personal care, and chemical manufacturing—but are adaptable for various applications. Filling machines efficiently fill containers such as pouches, sachets, bottles, and jars with liquids, powders, or granular products. The primary types of filling machinery include:
Augers and agitator fillers are designed for accurate dispensing of dry powders such as flour, sugar, coffee, and spices. These powder fillers feature a cone-shaped hopper that stores the bulk powder and uses an auger screw or conveyor, managed by an agitator, to precisely transfer product into pouches or containers. Auger fillers are paramount in the food, pharmaceutical, and nutraceutical industries where precision and consistency are critical.
The powder is placed into a pouch, typically made from poly or paper, which is formed using a collar. Packaging integrity is maintained as the pouch is sealed using a series of dies and heaters. The interface where the powder is dispensed must be carefully controlled for dust containment and efficient operation.
These systems deliver a combination of speed, versatility, and precision, making them ideal for accurately weighing and dispensing small components, granules, or mixed products. Each weighing hopper is precisely calibrated and integrates seamlessly with automated packaging lines for consistent output and minimal material waste.
Flow filling equipment is designed for volumetric filling of oils, syrups, sauces, and other free-flowing liquid products. These fillers incorporate nozzles and pumps to deliver high throughput while minimizing spillage. Typically, containers such as bottles and tubs are automatically indexed into place for precise filling, then conveyed to downstream packaging machinery for sealing or capping.
Tablet or capsule fillers are engineered for applications where items are counted rather than weighed. They utilize optical sensors or scanning technology to count pharmaceuticals (tablets, pills, capsules), confectioneries, or small hardware into bottles, blister packs, or jars. This ensures accurate product counts and compliance with packaging quality standards in regulated industries.
Positive displacement pump filling machines are highly versatile, accommodating a diverse range of container sizes, fill volumes, and product viscosities. Originally developed for semi-viscous and thick materials such as gels, lotions, creams, and pastes, these machines are ideal for food service, cosmetics, and industrial packaging. They can also be configured for thin liquids and fluids, providing gentle handling and precise volume control.
This machinery efficiently handles a spectrum of products, including sauces, dairy products, cosmetic creams, shampoos, honey, adhesive pastes, car wax, and specialty foods, ensuring sanitary, leak-free packaging.
Vertical form fill seal machines are advanced automated packaging systems widely used in the food, beverage, pharmaceuticals, and pet food industries. The VFFS process creates custom-sized stand-up pouches, sachets, pillow bags, or gusseted bags from continuous rolls of flexible film. These machines simultaneously form the package, fill it with product (liquid, powder, pellet, or granular), and seal it—all at high speeds.
The machine operates with a continuous roll of flat plastic film—often custom printed for brand recognition—which may include embellishments such as labels, tear notches, or zippers. Although plastic is the predominant material, VFFS machines are adaptable for metalized foil, composite materials, and even eco-friendly films. Prior to packaging sensitive products, films may be sterilized via chemical wash and drying to ensure hygiene standards.
Cartoning machinery—sometimes referred to as carton packing machines or carton sealers—forms, fills, and seals cartons or folding boxes. This vital equipment is found in food and beverage, pharmaceutical, cosmetics, hardware, and consumer goods packaging operations. Cartoning machines boost production throughput, reduce manual handling, and safeguard product quality.
Cartoning machines can be categorized into two main types:
Horizontally fed machines insert products into cartons from the side, while vertical cartoners fill units from the top. Both options can be integrated with robotics for automated product loading. Cartoners are relied upon for packaging products such as confectionery, cereal boxes, blister packs, pharmaceuticals, hardware, cosmetics, and food service items. Carton closing methods vary—options include tucking flaps, gluing, or adhesive sealing. Air-blast, mechanical arms, or manual operation facilitate product insertion, and carton coders or printers can add date codes and traceability information.
Pallet wrappers, also known as stretch wrap machines or palletizing systems, are essential for securing palletized loads in warehousing, distribution, and logistics operations. These machines use stretch film to wrap goods stacked on pallets, ensuring load containment, load stability, and protection during transit. Automated stretch wrapping significantly increases throughput while reducing labor requirements and packaging material waste.
A stretch wrapper guarantees that the correct amount of film, wrapping force, and number of layers are applied for maximum security and minimized risk of load shift or damage. Three major factors for optimal load containment include:
This machine rotates a pallet on a turntable platform while stretch film is dispensed and wrapped uniformly around the load. Turntable stretch wrappers are the industry standard for stable loads and support a range of manual, semi-automatic, and fully automatic packaging lines.
Turntable wrappers can be tailored to handle different load sizes, pallet weights, and application volumes, offering high throughput and efficiency in packaging warehouses and distribution centers.
With a straddle wrapper, the pallet remains stationary as a rotating arm applies stretch film around it. Straddle machines are best suited for tall, unstable, lightweight, or heavy and delicate loads. Their flexibility and handling capability make them indispensable in the beverage, paper, and food sectors.
Orbital wrappers, also referred to as "ringer" wrappers, wrap film around loads as they move horizontally through a rotating ring. These systems excel in packaging long or irregularly shaped products—such as carpets, metal extrusions, pipes, doors, and windows—providing customized wrapping solutions for challenging items.
High-speed rotary ring straddle wrappers can handle up to 200 loads per hour and are a staple in beverage, toiletry, and fast-moving consumer goods industries. These fully automated packaging systems minimize floor space and labor, delivering high efficiency for large-scale operations handling high-volume pallets or unstable loads.
In these machines, the load remains stationary while the wrapping system revolves rapidly around the pallet, ensuring secure and even coverage.
A shrink tunnel is a core component of shrink packaging lines and shrink-wrapping systems. When set to the correct temperature, it evenly shrinks a heat-sensitive film—such as polyolefin, polyethylene, or PVC—around a product for tamper-evidence, improved shelf appeal, and unitizing multiple items together. The process involves conveying the wrapped product through a heated tunnel, causing the film to contract tightly around the object.
Airflow within the shrink tunnel prevents overheating and ensures even application of heat. For high-sensitivity or perishable goods, special heat-sensing tapes verify temperature compatibility for safe packaging. If a product cannot tolerate tunnel heat, packaging specialists may recommend cold sealing, shrink bands, or alternative protective packaging methods.
Carded packaging machines automate the creation of packaging formats where products are secured between plastic blisters or shells and a rigid backing, such as a blister board or card. The three main types of carded packaging are skin packs, blister packs, and clamshells. These retail packaging solutions maximize both protection and product visibility, enhancing shelf presence.
Blister packs are commonly used for fishing lures, electronics, batteries, and pharmaceuticals, safeguarding sharp or fragile products and providing tamper-resistance. Skin packaging, meanwhile, is ideal for tools and hardware, offering a close-fitting, form-sealed layer that locks products in place for retail display. Clamshells are popular for their resealable design and clear product view, frequently used in food, electronics, and toy packaging.
Blister packing machines are available in semi-automatic and automatic models, offering blister sealing, cutting, and forming functions for high-volume production environments. Rotating sections or feeding stations hold the blisters in place, and modern machines can integrate with printers for lot and expiry codes—essential for pharmaceutical compliance.
Whether filled automatically or manually, blister packages are completed by sealing a blister board or foil backer onto the tray with advanced heat-seal or pressure-sensitive adhesives—allowing for secure, tamper-evident packaging solutions.
Skin packaging machines use heated, formable plastic sheets that conform tightly over products on a backing substrate, typically a cardboard card. A vacuum draws the plastic down onto the items and backing, creating an airtight seal that provides product security and visual transparency. Skin packing is frequently used for hardware, automotive parts, and retail display items due to its tamper resistance and merchandising benefits.
This packaging process ensures products remain fixed during transport, while displaying contents to end-users for easier evaluation and selection at the point of sale.
Clamshell packaging differs by consisting of a single piece of molded plastic, which hinges to enclose an item securely. Clamshell packaging equipment automates the joining, closing, and sometimes heat sealing of the two halves, ensuring a tamper-evident and theft-resistant package. These machines can seal with staples, RF welding, ultrasonic sealing, or heat, and are used extensively in the retail, electronics, and consumer goods industries.
Automatic lid-closing mechanisms boost productivity but may require additional floor space in high-throughput facilities.
Automated case erectors are integral to end-of-line packaging systems, rapidly forming and sealing corrugated boxes for shipping and distribution. Case erectors are available as manual, semi-automatic, or fully automatic machines that unfold, square, and seal boxes—eliminating the need for time-consuming manual assembly. These machines maximize efficiency in pick-and-place, order fulfillment, food processing, and e-commerce operations.
Semi-automatic erectors assist with box forming and conveyance, while fully automated versions use robotic systems to accomplish all stages hands-free. Once erected and filled, cases can proceed to case sealers or palletizing systems for final shipment. The choice depends on packaging line speed, box types, and labor resources.
The different types of packaging equipment support a complete packaging system by enabling code marking, traceability, tamper resistance, product identification, and efficient bulk materials handling. Key equipment types include:
CO2 lasers and fiber lasers are integral in packaging for engraving, cutting, marking, and coding various packaging materials such as paper, cardboard, plastics, and composite films. This laser machinery delivers high precision, speed, and flexibility, supporting both functional and branding requirements—including trace codes, unique identifiers, decorative elements, and anti-counterfeiting features.
The laser beam vaporizes or melts packaging substrates along high-precision paths, achieving clean, smooth, and accurate cuts for features such as easy-tear openings, vent holes, and custom windows. Laser die-cutting reduces the need for mechanical tooling, speeding up packaging design changes and enabling intricate package customization for food contact packaging, medical devices, and specialty boxes.
Laser cutting also streamlines downstream assembly, offering a competitive advantage in short-run, prototyping, and complex packaging formats.
Laser engraving and laser marking introduce permanent batch numbers, barcodes, date codes, and tracking information onto packaging materials. Laser marking achieves this by altering the surface of polymers, foils, or coated papers, while engraving ablates or etches into the substrate for greater depth and tactile feedback. Such coding is essential for supply chain management, anti-counterfeiting, and regulatory compliance—especially in pharmaceutical, food, and industrial packaging lines.
Laser-marked logos, batch information, expiry dates, and safety symbols enhance traceability and brand integrity, reducing the risk of tampering, recalls, or compliance violations.
A label is a vital component of package identification and traceability. Labels can be composed of plastic film, paper, metal, or fabric, and contain crucial product information, regulatory markings, branding, barcodes, RFID chips, QR codes, and other variable data. Labeling machines apply these labels with high speed and accuracy, ensuring compliance and consistency throughout packaging runs.
Besides regulatory and marketing information, labels can carry tamper-evident or security features, promotional content, instructions, and multilingual requirements tailored for international distribution.
A pallet is a load-bearing platform used for consolidating, storing, and transporting stacked goods during warehousing, shipping, and logistics operations. Pallets improve material handling efficiency, protect products during shipment, and are compatible with automated packaging, conveyor, and palletizing lines. Goods are typically stabilized and secured with stretch wrap, banding, or shrink film prior to transportation and storage.
Pallets are available in different materials, including wood, plastic, metal, and even recycled paperboard, each offering varying degrees of strength, hygiene, and sustainability. The right pallet solution can help reduce freight damage costs and increase distribution center efficiency.
The marking process references the application of regulatory, descriptive, shipping, or safety information directly onto packaging or external shipping containers. This may include hazardous material markings, international shipment identifiers, product specifications, and industry-compliant codes such as UN numbers or proper shipping names for dangerous goods. Marking ensures safe handling and legal compliance during transport or storage.
A collaborative robot (cobot) is a programmable robotic arm designed for close human-machine interaction on packaging lines. Cobots automate repetitive tasks such as part loading, case packing, palletizing, sealing, and quality inspection—improving speed and workplace safety. Many robots feature advanced sensors, vision systems, and AI that adapt to changing product mixes and reduce operational downtime in high-mix, low-volume packaging environments.
Equipped with safety technology, collaborative robots sense human proximity, automatically slowing or pausing to prevent accidents. Their agility and learning capabilities allow manufacturers to quickly reconfigure packaging lines and maintain productivity without significant manual intervention.
Packaging suction cups are vacuum gripping devices integrated into robotic and automated packaging systems. They enable fast, contact-free picking, placing, or transporting of a wide variety of packages, including fragile, irregularly shaped, or contaminant-prone products. Suction cups help speed up secondary and tertiary packaging tasks, reduce product damage, and maximize material handling flexibility.
The innovative design allows suction cups to function on clean, oily, wet, or uneven surfaces, making them suitable for corrugated cartons, shrink-wrapped trays, bottles, and flow packs. Material options include nitrile, neoprene, polyurethane, silicone, Viton, vinyl, and natural rubber, with each offering unique advantages in terms of grip, flexibility, and chemical resistance.
Types of packaging suction cups include:
The above suction cup varieties support packaging automation by enabling rapid, gentle handling of diverse packaged goods. For unique or industry-specific needs, custom engineered suction cups are available, supporting high-performance material handling in food, pharmaceutical, consumer goods, and e-commerce fulfillment environments.
This chapter explains what to evaluate when buying packaging equipment, how those decisions connect to real-world applications, and why the right packaging machinery can improve throughput, consistency, and overall line performance.
A summary of considerations when purchasing packaging equipment are:
These considerations can be further elaborated and discussed as follows:
Buying directly from an equipment manufacturer is common because OEMs typically understand their packaging machinery at a deep technical level and can provide detailed guidance on specifications, configuration options, and proper setup. This can be especially helpful when a packaging line requires custom changeovers, special sealing requirements, or integration with conveyors, coding systems, or case packing equipment.
However, it is important to recognize that manufacturers may naturally favor their own solutions when recommending equipment types, features, or brands. Distributors can provide a wider range of packaging equipment options across multiple manufacturers, which helps buyers compare performance, pricing, lead times, and service programs more objectively.
Depending on factors such as location, budget, and existing infrastructure, distributors may or may not be the best choice for your company. In many cases, the strongest approach is to evaluate both OEMs and distributors so the final selection balances equipment capability, long-term service support, and the total cost of ownership.
Selecting packaging machinery involves numerous considerations, with the type of materials being among the most crucial.
In addition to equipment and materials, the operational environment is also a critical factor. Working with a distributor offers access to a wide range of options and provides valuable guidance, advice, and product acquisition support.
Extreme temperatures can affect packaging quality, machine performance, and material handling, especially for film-based processes such as shrink wrapping and stretch wrapping. Very cold environments may stiffen films and reduce seal consistency, while high heat can soften materials, increase wear, and affect adhesives, labels, and product stability. Packaging equipment operating in these conditions may require properly sized cooling, heating, or insulation systems to maintain consistent operation and reliable package integrity.
No customer wants to deal with pneumatic machinery. Not only is pneumatic equipment outdated, but it is also environmentally unfriendly due to its high electricity consumption.
Many modern machines have reduced or eliminated pneumatic components, which can lower operating costs since compressed air is one of the most expensive utilities in most plants. Reducing pneumatic dependence can also simplify maintenance and reduce downtime caused by leaks, worn cylinders, and air preparation issues.
By removing pneumatic parts, companies can reduce expenses related to replacing and disposing of worn-out air cylinders. Additionally, some machinery incorporates "lean technology" to reduce film breaks and improve load containment, which helps prevent re-wrapping, lowers scrap, and reduces material waste. These systems often rely on more precise film delivery and better tension control to improve wrap consistency.
Considering eco-friendly materials is also important. While many metals used in packaging machines can be recycled, some materials cannot be recycled or are not typically recycled.
Moving packaging equipment is more than a physical relocation—it can impact throughput, safety, utilities, and line efficiency. Early planning is recommended because factors such as machine weight, floor loading, electrical requirements, air supply, controls wiring, and line flow can create installation delays if they are not addressed in advance. The placement of each machine in relation to upstream and downstream processes also affects changeovers, labor movement, and product handling.
To ensure a smooth and efficient installation, certain machinery should be installed in a specific sequence according to the flow of the packaging line. It is essential for a technical service contact or company to determine the order in which machinery should be moved.
Packaging machinery is a major investment, and many buyers feel uncertain or underinformed when comparing acquisition options. One of the most important decisions is whether to buy or lease equipment, since each approach affects cash flow, upgrade flexibility, and long-term cost. Leasing can help companies preserve capital while deploying needed production capacity quickly, while purchasing may offer lower lifetime cost and more control over modifications and maintenance strategy.
Considerations that will help determine the best option for a packaging line include:
It is crucial to research and evaluate at least three suppliers, considering several important factors for each. Comparing multiple suppliers helps validate equipment fit, service capabilities, material performance, and the long-term support needed to keep a packaging line running efficiently.
Location – Choosing a packaging machine supplier close to your company's location can facilitate quicker response times for emergency services or repairs.
Technicians – Ensure that the supplier employs certified and experienced technicians who are trained to work with packaging equipment and can support installation, troubleshooting, and preventive maintenance.
Customer Service – While it might be tempting to choose the cheapest option to cut costs, selecting a supplier with poor customer service can negate the savings. Slow response times, weak technical support, or unclear service policies often lead to additional expenses and extended downtime.
Cost – Compare the cost and quality of materials, as lower-cost films might have less clarity, weaker seals, or reduced puncture resistance, while higher-cost materials may improve performance, reduce waste, and lower rework rates.
Parts – The frequency of machinery use will affect downtime due to repairs or emergency services. Inquire about parts availability, lead times, and preventative maintenance schedules to minimize disruptions and protect throughput.
Packaging equipment is used in various applications, including:
Food – Ready-to-eat meals, grains and seeds, milk and liquids, spices, coffee, sugar, oil, salt, tea, bakery products, beverages, candy and confections, dairy products, and bakery items.
Pharmacy – Tablets, capsules, granulated products, oral liquid dosages, ophthalmic and ENT solutions, injectables, gels, and oral dosage powders.
Others – Agrochemicals, adhesives, fertilizers, lubricating oils, coolants, varnishes, paint powders, pet foods, hardware, cement and wall putty, pigments and dyes, foundry materials, inoculants, and flux.
Packaging equipment offers several advantages, including:
Production – A comprehensive packaging line can strongly influence operational success when high volumes must be packaged quickly and consistently. While the initial equipment investment can be substantial, optimized machinery improves repeatability, reduces handling errors, and supports scalable growth as demand increases.
Total Cost of Ownership – One of the key factors to evaluate is the total cost of ownership. Effective packaging machines can reduce reliance on manual labor, lower rework and material waste, and improve uptime through consistent operation. Even with a higher purchase price, automation often becomes the more cost-effective option when measured across labor savings, throughput gains, and reduced downtime.
Speed – Automated packaging systems can process more packages per hour than manual methods, helping companies meet shipping deadlines, reduce backlogs, and maintain service levels. For operations where delivery windows and production schedules are tight, packaging speed becomes a competitive advantage.
Reliability – Packaging machinery does not require time off and can operate continuously when supported by routine preventive maintenance. While mechanical issues can occur, planned maintenance and available spare parts help minimize unexpected shutdowns. This reliability reduces downtime risk and improves overall equipment effectiveness, saving both time and money.
Some of the disadvantages of packaging equipment include:
Cost – Packaging can increase production expenses and, in turn, raise the retail price of products. In some industries, packaging can represent a significant portion of the final selling price. Developing new package designs or changing packaging formats can also require investment in materials, tooling, testing, and line adjustments.
Landfill Impact – Packaging contributes heavily to waste production, and many materials are difficult to recycle due to contamination, multi-layer construction, or limited recycling infrastructure. Even when packaging is technically recyclable, real-world collection and processing limitations can cause a large portion of packaging waste to end up in landfills.
Production Footprint – Increased packaging can require more raw materials and energy, which may increase a facility’s overall environmental footprint. Packaging production and conversion processes also consume energy and can contribute to emissions and other environmental impacts depending on material selection, sourcing, and disposal practices.
Packaging equipment plays a critical role across virtually every industry, as it directly impacts production efficiency, operating costs, and overall product competitiveness. Well-designed and properly selected packaging machines reduce labor requirements, minimize material waste, and improve consistency throughout the packaging process. As packaging operations become more efficient and reliable, businesses can lower per-unit production costs, increase throughput, and enhance product presentation. Ultimately, higher-performing packaging equipment supports scalable growth, stronger market positioning, and increased sales by enabling faster, more cost-effective, and more dependable packaging operations.
Packaging equipment is used to protect, contain, seal, label, and prepare products for storage, transportation, and sale. These machines perform tasks such as filling, wrapping, sealing, coding, case packing, and palletizing, helping manufacturers improve efficiency, consistency, and product safety.
Common types of packaging machinery include filling machines, baggers, form-fill-seal machines, shrink and stretch wrappers, carton sealers, case packers, palletizers, labeling machines, and coding and marking systems. Most packaging lines combine several machine types to handle different stages of the packaging process.
Packaging equipment is widely used in food and beverage, pharmaceutical, chemical, cosmetics, consumer goods, agriculture, and industrial manufacturing sectors. Each industry relies on specialized machinery to meet regulatory requirements, protect products, and maintain efficient production workflows.
Automated packaging equipment increases efficiency by reducing manual labor, improving packaging speed, and ensuring consistent package quality. Automation also minimizes errors, supports higher production volumes, and allows packaging lines to operate continuously with minimal downtime.
Key factors include product size, weight, and fragility; packaging materials; production volume; required speed; available floor space; environmental conditions; maintenance requirements; and integration with existing equipment such as conveyors or labeling systems.
Yes. Packaging equipment ranges from manual and semi-automatic machines for small or flexible production runs to fully automated systems designed for high-volume, continuous operation. Selecting the right level of automation depends on production goals and budget.
The main benefits include reduced labor costs, increased packaging speed, improved consistency, enhanced product protection, better hygiene, and lower long-term operating costs. Packaging equipment also helps companies meet regulatory and traceability requirements.
Common challenges include high upfront investment, maintenance requirements, material waste if systems are not properly optimized, and environmental concerns related to packaging materials. These challenges can often be mitigated through proper equipment selection, preventive maintenance, and efficient material usage.
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