Five Packaging Line Bottlenecks That Have Nothing to Do With Your Filling Machine

When a company needs to increase production speed, often the first thought is to get a faster filling machine. If more bottles can be filled quicker, a company must be able to increase production, right? But the bottle filler is not always the cause of slowdowns or production misses, and even the most advanced liquid filling machine can only perform as efficiently as the processes and equipment that surround it. Below are common non-filling machine issues that may cause a bottleneck or slowdown in production.

1. Inconsistent Container Supply

Before they can get filled by the liquid products, the containers have to make it to the filling machine in the proper orientation. If bottles are loaded manually or too slowly, then production will quickly become backed up. At Liquid Packaging Solutions, we manufacture loading turntables, laning conveyors, and other packaging equipment to assist with the delivery of the bottles, helping to ensure the container supply does not slow down the filling machine or any other part of the packaging line.

2. Poor Container Prep

Containers need to not just arrive on time and in the proper orientation for the filling machine, but also ready for the product! For some projects, this can mean using LPS rinsing machinery to clean out dust, debris, and other contaminants that could affect the product. Improperly prepped containers can lead to rejected containers or even quality control issues and the need for extra inspections, all of which can slow down the packaging process. Integrating the right rinsing or cleaning system will also help to maintain product quality while improving efficiency.

3. Conveyor System Limitations

Conveyors are thought of more than anything else as the equipment that moves bottles from one machine to another, however, they must be set up strategically to avoid accumulation and bottlenecks at the wrong places. Conveyors moving too fast or too slow can cause problems for the entire line, from jams and spills to slow and inefficient production. A conveyor system for any packaging line needs to be designed to balance speed and flow between rinsing, filling, capping, and other packaging tasks. LPS designs conveyor systems to complement the packaging process and the machines found on the line.

4. Capping and Sealing Delays

Another area outside of the filling machine that can cause delays is the bottle capper. Capping machines require precision delivery of the caps, proper placement and consistent and reliable sealing. Proper set up and routine maintenance can help to eliminate backups of the capping machine that will slow down not just the filler, but the entire line, as these issues, like the bottle rinser, can also lead to quality control issues, spills, and extended downtime. LPS capping machines are designed and manufactured to work with the chosen filling machine to keep bottles flowing through both machines.

5. Changeover and Cleaning Times

Production time can definitely be lost during the changeover phase from one bottle to another, which can include adjustments on the filling machine as well as every other component of a packaging line. The same is true of cleaning the line when changing products or performing routine maintenance. The LPS design uses quick, tool-less adjustments on all equipment wherever possible, helping to reduce changeover times. Equipment can also be manufactured for quick cleaning as well, including Clean-In-Place (or CIP) systems on filling machines. Improving changeover efficiency and reducing downtime always helps to hit production goals.

A packaging line functions as a complete system, and one that is only as productive as its least productive component. While issues with a filling machine can lead to downtime and missed production goals, packagers should look deeper to make sure the lack of efficiency is not caused by another part of the complete line. To learn more about packaging lines, integration and maximizing the total efficiency of your own packaging system, call and speak with a Packaging Specialist at LPS today!