Cross-study comparison of Automation in Packaging study

Packaging equipment manufacturers are a relatively small group doing highly specialized work. Almost every product has different requirements for packaging, and the equipment used to manufacture, fill, seal, convey and pack it. Many packaging projects are totally customized, and processes are becoming increasingly automated.

By Control Engineering Staff December 1, 2008

Packaging equipment manufacturers are a relatively small group doing highly specialized work. Almost every product has different requirements for packaging, and the equipment used to manufacture, fill, seal, convey and pack it. Many packaging projects are totally customized, and processes are becoming increasingly automated.

Why are the packagers not using all the automation features offered on packaging machinery they have purchased?

OEMs Integrators
Knowledge level of workforce 77% 78%
Automation features exceed client needs 57% 71%
Features too complicated to operate 39% 47%
Lack of compatibility with existing systems 38% 29%
Packagers understaffed 18% 12%
Not sure 14% 10%
Slows operations 11% 10%

Flexible packaging systems should be better leveraged to improve time to market

Study 1 Packagers Study 2 OEMs Study 3 Integrators
Completely agree 40% 38% 67%
Somewhat agree 47% 50% 29%
Somewhat disagree 10% 10% 4%
Completely disagree 3% 2% 0%

Main reasons to automate packaging processes

Study 1 Packagers Study 2 OEMs Study 3 Integrators
Multiple choices allowed na = data not available
Control labor costs 81% 77% 80%
Flexibility (handles various sizes/configurations) 45% na 16%
Gain production efficiencies 74% 52% 55%
Gain competitive edge 49% 28% 29%
Reliability 47% 23% 18%
Machine flexibility (easily changed packaging types) 38% 27% 8%
Machines are outdated, need to be updated 34% 22% 33%
Price 34% 19% 8%
Reduce material waste na 9% 6%
Energy management na 6% 16%
Sustainability 34% 11% 6%
Footprint (size of machine) 18% 3% 2%

Which of the following automation and control product features are most important when deciding which components to include or deciding which vendors to use?

Study 1 Packagers Study 2 OEMs Study 3 Integrators
Multiple choices allowed na = data not available
Reliability (e.g. performance) 71% 54% 55%
Quality/durability (e.g. long lasting) 63% 33% 39%
Price 61% 42% 18%
Easy to use, install and maintain 57% 31% 31%
Price-to-performance value 52% 35% 45%
Compatibility with existing systems 48% 32% 27%
Long term cost of ownership 41% 14% 18%
Product specifications 35% 19% 24%
Products performed well during in-house testing 37% 16% 4%
Lot tracking/tracing capabilities na 5% 2%
Enhances speed of line changeover 36% 6% 10%
Scalability 16% 3% 10%
Offers development tools 12% 5% 2%
Other 3% 3% 2%

For other results, also see:

Automation helps packagers: Webcast, research, 3-part article series

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