Old VS New - A guide to buying new or refurbished packaging machine

Production department insists on new equipment, the financial department tries to cut costs, and it is the decision is up to you: should we purchase a new or a refurbished machine? In all “old vs new” dilemmas price is always the main factor, but you need to consider other factors in order to make the right packaging investment.

If you are a startup business that wants to test product and packaging concepts at a reduced cost - refurbished machine might work. Used machines are usually available quicker and they cost less. But... The machine you purchased can turn out to be inefficient and unreliable.  Are there spare parts available and can they be acquired easily? Can a refurbished machine meet safety standards that are constantly rising? Are you going to have to invest in expensive modification in order to make the machine work for you? What about warranty?

If you still insist on getting a second hand machine, make sure to keep an eye on these four things.

1. Do a complete audit of the machine including the electrical components.

2. Find out about the history of the machine; what products were run on it? What was the plant environment? Was maintenance performed on it regularly?

3. Look for oil leaks – they are a sign of a poorly maintained machine.

4. Always demand to see the machine in full operation, so you are sure that all functions work.

A new packaging system is the ideal solution for established companies that want to improve packaging efficiency.

These companies are more interested in improving packaging speed, packaging quality and overall efficiency of a production-line, since they already have a defined and standardized packaging processes.

True, this demands initial capital and investment costs are higher, and with some manufactures it may take a bit longer for machine completion.

But, on the other hand, you will get a piece of equipment that is designed and optimized specially for you, so it can serve you for many years to come. The new machine is compliant with all current safety requirements, it has a genuine warranty and with a good manufacturer, you don’t have to worry about regular maintenance, service personnel or spare parts.

So, here's the 8 advices you should follow when you consider buying a new packaging machine.

1. Research Online, Purchase Offline.

Use the internet to educate yourself and learn about new modular features of packaging machines and packaging techniques that may interest you in the future. Narrow your choice down to two or three manufacturers and models that could meet your needs.  Don't spend a little time in communication with many manufacturers,  take your time and get all the important information from the few manufacturers you contacted.

2. Be a Value Shopper - Not a Price Shopper

Don't be too rigid about the right price, or you might end up with the wrong machine. Ask about certain modular add-ons you can buy later. This will allow you to move up in features as your business and budget grow, without losing a big part of your initial investment. A good manufacturer should provide a way for you to upgrade your equipment.

3. Ask About Warranty and Services

Check if the manufacturer you chose can provide you with satisfactory warranty, spare parts and servicing of the machine.

 4. Expect and Embrace Training

The more complex the packaging solution is, the more valuable a well-educated support team will be. Proper training can help you to explore new possibilities and find the best way of utilizing your new packaging machine.

5. Try Before You Buy

A good demonstration and testing are mandatory! Demand to see the machine working with a variety of products and packaging types, utilizing all the features you required.

6. Allow Yourself Room to Grow

Purchase a machine that allows you room to grow. Even if you have only a small interest in expanding your product line, ask about the ability to add the features that will allow you to pack your potentially new product in the future. Some features can be added as an after-purchase, while some will require an entire change of models.

7. Trust Your Instincts

Which manufacturer seems more appealing? Who is the most suitable for a long term relation? After all, you are investing in an entire packaging environment, not just in a packaging machine. Make your purchase where you feel at home. Will you be at ease contacting the manufacturer and asking for help? Is technical help readily available?

8. Always Consider a Manufacturer's Reputation

How committed is the manufacturer  to you as a client? Are they set out to make the initial sale with a focus on building a long term relationship, or do they assume they won’t be seeing or hearing from you in a while? Do they offer a full line of products and services that support your business? Are they structured as a onetime stop for acquiring the machine, or as a potential lifelong partner in all your packaging endeavors?

We won’t tell you that Tishma Technologies should be your first choice. Just follow these steps. We look forward to cooperating with you.

Do not let the potential price discourage you in getting a new machine. With a modular approach to design, the price of a new machine isn’t always significantly over your budget. Go ahead and ask a reliable manufacturer for a quote. You can start by checking out Tishma Technologies’ cartoners, case packers, tray packers, palletizers and robotics - whichever you need, Tishma will deliver!

Advantages and Add-ons for modular packaging systems

 Modular design is an emerging trend in the world of packaging solutions. With the modular approach, all elements have a Lego  like configuration, so that various ehancments can be arranged and combined to fit the application. There are various modular add-ons for a packaging line, but here are the 9 most common ones that can make your packaging process much faster, efficient and cost effective. 

1.            Automatic Bottle Loader

Bottles are received on a conveyor, the presence of a bottle is detected and will call for a carton to be erected (no bottle no wasted cartons). Automatic bottle loading requires less manpower and it makes the packaging process more efficient.

2.            Automatic Leaflet feeder

 The automatic leaflet feeder can automatically collate and insert literature in the package at very high speeds, so you don’t have to do it manually

3.            Ink Jet or Laser printer

 An InkJet Coder is used to mark the package with very important, trackable information with the help of a jet that shoots ink in a pre-determined pattern.

Laser Coding is an enhancement for a packaging machine which marks packages with a help of a laser beam programmed to produce a code or date onto the package.

4.            Glue or tuck closing

Tuck closing add on is a closing system which closes a package, usually a carton, using pre-cut tabs and slots.

Glue Sealing add on is a sealing system which uses adhesive to seal cartons or corrugated cases and provides tamper evident security for these packages.

5.            Automatic product feeding system

 The high volume of products require feeding systems that can accept products from the manufacturing process and deliver them to the packaging machines without manual labor.

6.            Robotic product loading

 Robotic feeding systems are highly efficient and flexible, enabling quick adaptations and changes with the minimum possible cost, supporting the initial investment.

7.            Net weigh scale interface

 If packaging accuracy is low, it means packages are going to be over filled, which will result in an excessive product give-away. That is where scales come in. 

8.            Volumetric filler

 Volumetric cup fillers measure out a product, usually free-flowing solids or powder, in a cup of specific, predetermined volume.  Its great for products like rice, candies or frozen peas, which do not generate dust.

9.            Auger filler

 An Auger Filler is a filling mechanism  for powder or free flowing solids, which measures out a product with a help of an auger which is rotated for a predefined number of revolutions in a conical hopper to discharge the required volume of product. It is used extensively for powders and dusty free flowing solids. 

As you can see, modular design allows you to think outside the box and "build" your own machine - a packaging system designed according to your needs. Still not convinces? Well, here's the main 5 reasons why you should go modular with your packaging equipment:

1. Saving floor space

Usually, after purchasing all the machines necessary for production, the remains of the floor space are used for packaging equipment. These spaces are often unusual and tight, and that's where modular design comes in. What once would have been an in-line machine now can be redesigned in different layouts to fit the requirements.

2. Hybrid Technologies

Modular packaging equipment allows you to turn on or off some machine operations, depending on a current application. For example, you can integrate a robotic palletizer under the same controls as other operations (case erecting/loading), and use it when you need it.

3. Development time

The development time is often lower because once the design is split up into modules, design teams can work at the same time on the different modules.

4. Reasonable price

For a packaging machine that will be built from scratch, you are about to pay development costs as well as production costs. With a modular design, you covers only production expenses, since most of the modules have already been developed.

5. Tailored Standardization

Tailored standardization enables manufacturers to construct the right solution with standardized parts of different sizes. You get a right-sized solution built according to specific requirements, and manufacturer still enjoys the benefits of economies of scale.

We introduced you with wide range of possibilities that come with a modular approach to packaging equipment, and now it is up to you to find the most reliable packaging machine manufacturer to develop a solution for you. Every packaging line, machine or system can be enhanced with these modular add-ons in order to meet your specific requirements. Start your research with Tishma Technologies’ cartoners, case and tray packers and palletizers – each of them available with their unique set of modular add-ons.

4 lessons hidden in a K-cup by Tishma Technologies

We are sure you have heard about the most popular single-serve coffee container for coffee brewing – the famous, yet controversial K-Cup! Today,  many homes and offices have K-Cup machines for individual serving size and flavors, which is why entering this competitive market might seem so appealing. K-Cups brought revolution. The coffee pods’ share of total coffee sales in 2000 was almost negligible, but, with the launch of K-Cups, this market was taken by storm, commanding a strong 34% share of total coffee sales in 2014.

When it comes to packaging, K-Cups are quite an inspiring topic. There are many useful lessons we can learn just observing K-Cups, their development and principles they apply. So, what are the most important lessons we can extract?

K-cup: How it works? by Tishma Technologies

1.        Be creative - Package as an innovation

Innovative packaging can help a product penetrate new markets and it can also change the way consumers perceive a product. Just like stick pack revolutionized the way we use sugar (learn more here), Keurigs coffee machines and K-cups introduced an entire new way of brewing coffee, forming a new market.

Lesson? Be creative and persistent with your ideas! At first, the creators of K-cups were making the pods by hand. The prototype brewing machines were a work in progress and unreliable, and the company needed funds for development. After numerous pitches to potential investors, they finally got $50,000 from Minneapolis-based investor Food Fund in 1994, and later the Cambridge-based fund MDT Advisers contributed $1,000,000.

2.     Be economic - Space saving

K-cups are transported and stored in carton boxes, packed in a certain manner that saves space. Good K-Cup packaging system can invert every-other cup, so the cups interleave and minimize space usage in the box, so that means more K-cups can fit into one carton. This is exactly how you should treat your floor space when you are purchasing any type of industrial line. No matter how big your space is, why cluttering it with huge machines and massive pieces of equipment? Look for a manufacturer that can cater to your specific needs and create a custom solution with respect to your floor space.

3.       Be eco-friendly - Recycling

Unfortunately, K-cups fail when it comes to recycling. The K-cup system has a lot of quite demanding technical requirements: being able to withstand a certain amount of temperature, to have a certain kind of rigidity, to provide the right kind of moisture barriers and oxygen barriers etc. So, recycling isn't the easiest challenge. Keurig has been publicly criticized by environmental activists and journalists for the billions of non-recyclable and non-biodegradable K-Cups, which end up in landfills. Prevent this from happening to you! Being eco-friendly and responsible towards the environment is the one of the top requirements for companies in the 21st century, so make sure your packaging is recyclable or biodegradable.

 

Be eco friendly by Tishma Technologies

4.       Stick with the original - Authenticity

Only licensed and standardized K-cups are compatible with Keurig’s coffee machines. There are a large number of unlicensed coffee pods  available in the market, but even though they are cheaper, their use is not recommended because they can cause damage to your coffee machine. Use of strictly licensed K-cups may seem costly in the short term, but in the long term it saves money, because it makes your coffee machine last longer. Same goes for acquiring printer cartridges, mobile phone chargers or spare parts for an industrial machine – always buy from a reliable manufacturer. This is the only way to be sure that materials or add-ons you bought are fully compatible with the system you already have.

So what is our final advice, after going through these lessons? If you want to get your share of profit in coffee brewing market, your next step is finding the right packaging system that will allow you to quickly pack and ship your K-Cups to the final users.

The most important requirement for K-Cup packaging machines is being able to handle the cups coming in, top –up, at a very high rate of speed (sometimes up to 900 cups per minute) and inverting every-other cup in order to save space.

Start by checking out Tishma Technologies TI 100 vertical Cartoner. TI 100 is a High-Speed small center vertical system with a patented computer scale interface or volumetric cup fillers for high speed cartoning of K-Cups. Our 100 Series Cartoners feature user-friendly PLC’s combined with mechanical, state-of-the-art simplicity, and besides K-Cups, they are also very convenient for Fruit Cups and Yogurt packaging.

From Forklifts to Robots by Tishma Technologies

Pallets and pallet handling, invented in the 20th Century, became one of the most significant logistics tools. Over the past century pallets continued to develop, thus enabling the evolution of modern logistics. Use of pallets brought important efficiency improvements in the handling and transport of unit loads. During World War 2, some additional improvements were added to pallet design and management.

Army logistics in WW2 by Tishma Technologies 

The first to take steps in developing new warehouse handling and storage methods was The Office of The Quartermaster General, Field Operations Branch of the Storage Division. They were faced with the big pressure and big responsibility: their new methods had to give results quickly. At the time, one manufacturer was able to deliver an amount of a fork trucks with a load capacity of 2000 lb.  As a result, the system was predicated on this particular truck, and the pallet of the Quartermaster Corps was designed to fit that truck load capacity. A standard Quartermaster pallet is 32 in. long and 40 in. wide.  A million or more of these were procured and placed in service during the following year.

As the time passed, manufacturers of fork trucks increased their production and the Quartermaster General procured the larger trucks for all services, making the use of larger pallets more common.

The Navy started its materials handling program in 1942.  By then, the manufacturers of fork trucks were in quantity production, so the Navy ordered more of the larger trucks with load capacity up to 15,000 lb.  This is why the pallets made for inter-depot and overseas shipment are bigger: they are standardized on the 48 x 48 in. for inter-depot and overseas shipment, and 42 x 66 in. pallet for the intra-depot movements

According to some experts’ predictions, somewhere between one million and three million pallets will be disposed of by the government once they are no longer needed by the Army. The largest volume will be in the 32 x 40 in., 48 x 48 in. and the 42 x 66 in. sizes. Some of the 42 x 66 in. pallets will be picked up by stevedoring companies for use in marine terminals, and other pallet sizes will be used by manufacturers who are now learning the value of this shipment.

Before the Army ordered so many pallets, industry had been reconsidering building pallets of light, cheap construction, so called “single shippers,” intended to carry one load and then be discarded as scrap lumber, but since a large surplus of pallets is expected, this cheap “one use” type of pallet will not be developed.  Instead, the industry is probably going to absorb the surplus pallets.

 

Palletizing than and now by Tishma Technologies

Many companies utilize pallets for shipping and stacking of their products and since manually placing boxes on pallets can be time consuming and expensive these companies turn to automatic palletizing systems. If you still haven’t, consider investing in a good, automated palletizing system built to meet your needs, check out robotic Palletsizers by Tishma Technologies.

Who invented a cardboard box?

Have you ever imagined how the world would look like if the cardboard box was never invented? How would you pack for moving to a new place? How would Amazon deliver their goods to you? This four angled, square shaped invention spontaneously became a symbol of transport, protection, efficiency and change. But who is to be credited for this innovation, and when did it all start?

Corrugated (also called pleated) paper was at first used as a liner for tall hats, and it was patented in England in 1856. Fifteen years later, on the 20^th of December, 1871, first corrugated boxboard was patented and used as material for shipping containers. Credits for inventing a single-sided corrugated board are given to Albert Jones from New York City and three years later, Oliver Long improved Jones's design by adding liner sheets on both sides of corrugated board creating a design that we know today.

In 1874, G. Smyth built the first machine for producing bigger amounts of corrugated board, but it took 15 years for people to start using this new material to create a case packaging.

In 1890, a Brooklyn printer and paper-bag maker, Robert Gair invented the pre-cut cardboard box. He came to this invention by accident. One day, while he was printing an order of seed bags, a metal ruler which is used to crease bags changed position and cut them. Gair then discovered that by cutting and creasing at the same time he could make prefabricated paperboard boxes! This idea was applied to corrugated boxboard when the material became available around the turn of the twentieth century.

In 1915 John Van Wormer of Toledo, Ohio, took the credits for inventing first "paper bottle," - folded blank box for holding milk he called "Pure-Pak." The fact that milk carton could be folded, glued, filled with milk, and sealed at a dairy farm was considered a great innovation at the time. Increased demand for lightweight flaked cereals lead to the rise in the use of cardboard boxes and first company to use cardboard boxes as cereal cartons was the Kellogg Company.

During all this time, Japan was way ahead of Europe and USA when it comes to the use of cardboard boxes. Since 1840, Japanese silk manufacturers have been using these boxes for transporting the Bombyx mori moth and its eggs from Japan to Europe.

Today, cardboard cases became an immediate association for shipping and stacking of various goods. Close to 100 billion boxes are produced each year in the U.S. That is a lot of boxes and just imagine all the time and money that can be saved if each of those boxes was filled by efficient and economic packaging line! For more on Tishma Technologies case packaging systems, please click here.

Shelf ready packaging – Do you fit the requirements?

It seems unbelievable, but good choice of secondary packaging can help you increase your revenue up to 35%! Not only that, but good secondary packaging can make your resellers embrace and support your product, because your packaging helps them to keep in-store logistics more efficient and economic.  Secret lies in shelf-ready packaging, or shorter: SRP.

Main task of shelf-ready packaging is delivering your product to a retailer, packed in a special unit that can be easily placed on the shelf without unpacking or repacking.

Most SRP solutions typically consist of a tray and a cover, and they are made out of corrugated cardboard.  

Tray Packaging by Tishma Technologies

There are 5 conditions that need to be fulfilled in order for your packaging to be considered shelf-ready: easy identification, easy open, easy dispose, easy shelf and easy shop.

1.       Easy identification helps the store staff to select the right products; it allows faster filling of the shelves and it reduces placement error in the stockroom and in the store.  Product, product code, content, versions and expiration date must be clearly visible on the SRP. If products are placed on a pallet, make sure they are arranged and aligned so that brands can be seen.

2.       In order to secure easier and quicker replenishment, every shelf-ready packaging must be easy to open. Consumers are influenced by sight of overcrowded aisles and out-of-stock situations and to avoid slow and inefficient replenishment, a good SRP needs to be easy to open without use of any tools. It also has to be robust enough to ensure safe transport through the supply chain.

3.       SRP should be easy to dispose with minimum interaction, and no assistance. In order to save space, empty SRP’s should be foldable. Minimal disposal time and responsibility towards environment are mandatory and they can be accomplished through reduction of material for SRP. Don’t forget to put clear instructions for its return or recycling!

4.       Shelf ready packaging also means that your secondary packaging can easily be placed on a shelf, without losing its stability and original shape. Integrated handles can make the placing of goods easier, and to avoid out-of-stock-situations, two SRP should be placed on one shelf.

5.       Consumers will also interact with your secondary packaging, and it is up to you to make that interaction easier. Consumers need to easily locate their desired product inside and easily remove it from the SRP. Front panel of a SRP should be used to show the products included in the SRP.  Keep your SRP in bright colors, so that it attracts the attention of customers and make sure relevant information from the primary packaging are also provided on SRP. Don’t arrange your products too close in a SRP and do not stick them on the tray so that a customer can easily take or return the desired product to the SRP. Remember, SRP’s must remain visually appealing and stable even in a half-empty state.

5 Requirements of Shelf-Ready Packaging by Tishma Technologies

All of the numerous advantages of shelf ready packaging start with a good packaging line. If you have decided to make your secondary packaging shelf-ready, look up for Tishma Technologies Tray Packers, available with tuck and glue closing, accumulation conveyors, small overall footprints and user-friendly HMI operator interface.

Dress to impress: Candy Packaging Tips by Tishma Technologies

So you entered the candy manufacturing business? That means it is the perfect time to invest in a reliable packaging line. Of course, you shouldn’t judge a candy by its packaging, but according to a Nielsen’s 2016 study, candy needs to be “dressed to impress”.

The Candy industry has come a long way since the packaging was just a way to maintain safety and hygiene. Today, packaging is also an important marketing tool. The Study conducted by Nielsen in 2016 gave the candy packaging industry new insights, and it is a matter of time until manufacturers all over the world start to apply the Nielsen findings to their packaging designs.

The Top aspects of candy’s packaging that made the most impression on the consumer, according to this study, are visuals, in the following percentage: the image of the product (51%), a window that shows the actual product (49%), logo or brand name (46%) and the color scheme of the package (41%). 

The main goal of every packaging design is to stand out from the competition and win the battle for consumers’ attention, while keeping it original. For example, if two or three brands’ packaging features the color yellow (because they all heard that yellow draws the most attention) then the color is no longer making a distinction of the brand, and it certainly doesn’t draw attention.

Sometimes distinction is accomplished through experimenting and innovations that have not yet been seen on the market. It could be innovative packaging format like mini single-serve packaging, standup pouches, re-sealable packaging or shareable packs. It could mean new materials, specific colors or artwork. The Sky is the limit, but remember, experimentation can be risky! Sometimes it can cause consumer backlash for legacy brands, with consumers passing over the new packaging for other more visible varieties.

If you feel like pioneering a new packaging design, know that it won’t be long before other manufacturers start implementing your innovation across the category.

On the other hand, secondary packaging can indirectly help you to drive sales. The more common packaging solutions for candy are Horizontal and Vertical Cartoning Machines (check out cartoners by Tishma Technologies on the following link: https://goo.gl/nKLHwO). These machines make shipping and stacking of candy much more efficient, and well-chosen, shelf-ready secondary packaging enables easier identification of your product, easy shelf placement and easy extraction of product from the packaging by consumers.

When you have a good packaging line, all you need is a sprinkle of innovation and then you can enjoy the taste of success - sweet as the candy you manufacture.