February 2021

In today’s economic environment, most companies are aiming to lower their handling costs as much as possible. Automated bulk handling systems make work easier, more timely and effective, and can help to reduce the number of workers needed to perform a task, thus helping manufacturers to lower costs.

In this article, we will discuss the benefits of a well-designed automated bulk handling system.

What is an Automated Bulk Handling System?

Automated bulk handling systems are specialised systems that are built for a specific purpose. It enables manufacturers to manage very high-volume output with minimal manual intervention. These systems are typically designed to manage certain product runs, whether continuous or as batches. The output ranges from individual products to combined products comprising multiple packages. In Australia and New Zealand these systems typically handle product packages up to 1 ton in weight.

The Advantages of an Automated Bulk Handling System

In any form, high-volume handling poses significant challenges for manufacturers. There are three main issues that need to be addressed during the production process.

1. Labour Efficiency and Increased Safety

For instance, the labor required to perform this bulk bagging by hand is ergonomically challenging, while the time and risk quickly adds up to even higher cost. Manual bagging injuries cost companies millions each year in medical costs and lost labour.

A fully automated bulk bagging systems offers the solution to this challenge, helping businesses to deliver maximum efficiencies at all stages of materials handling. The machine does all the heavy jobs that often exposes staff to injuries, such as filling and palletising. By doing so, you are freeing up your staff from tedious and unproductive duties so they can do more valuable work.

2. Reduce Human Errors

Other reasons why companies would benefit from an automated bulk handling system is to reduce errors caused by humans. When doing repetitive tasks, the human brain is likely to switch into “auto-pilot” mode, meaning we are not paying full attention to the tasks in our hand. Not surprisingly, overfilled bags are very common in warehouses that still use manual labor. Contamination and product mishandling are other common issues as humans sometimes make mistakes when storing and handling equipment or materials.

An automated bagging machine lowers the risk of human error, as each bulk bag is weighed, filled, and sealed automatedly by the system. The machines are less likely to mishandle expensive materials and will be able to keep its environment sterile at all times, thus you don’t need to worry about the aforementioned issues. 

3. Time-Saving Benefits

While increased demand for output is always welcomed by any businesses, increasing production to meet the demand is not as easy as it sounds. You can’t just increase your labour by tenfold or expand the areas of production overnight. Moreover, human laborers need to take snack or meal breaks every few hours, as well as many toilet breaks, which could add up to 1-2 hours per day.

On the other hand, a bulk bag filling machine doesn’t need rests in order to function properly, and you can easily program it to fill more orders in less time. Moreover, the machines can improve cycle times, since the material doesn’t need to wait to be transported by a human operator. The time it takes to complete one production cycle becomes shorter and more predictable, which helps to improve cycle time estimates and allows for more accurate due date estimates for customers. 

Therefore, during a period of high demand, you can confidently rely on these machines to finish the job. Be sure to get yours from a trustworthy bag filling machine manufacturer to avoid potential disruptions and ensure a smooth packaging process..

Conclusion

The more efficient your handling is, the lower your bottom line costs will be. Efficient use of labor, reduced excess inventory, better timing and product control, and timely delivery are some of the benefits of having an automated bulk handling system for manufacturers. This is especially helpful with high-volume manufacturing. Moreover, these bag filling machines work diligently and timelessly, which allows you to gain more productivity and value out of every dollar invested. 

Therefore, there’s no doubt that automated bulk handling machines is the right way to go for your company in the long term. At Aurora Process, we can help you with industrial packaging systems from start to finish – be it filling, closing, conveying, palletizing, wrapping. If you are looking for a bulk bagging machine, be sure to contact us today.

As a manufacturer or distributor, handling increased demand is challenging. Determining the right time to automate your packaging line requires thorough research and analysis. Luckily, there are many common signals that tell you when it’s time for your company to automate its packaging process.

Here are 4 common signs that your company is ready to automate its packaging line.

You Can’t Keep Up with Demand

One of the top reasons companies inquire about industrial packaging equipment is when they fail to keep up with increasing demand. As a result, vendors are getting angry, employees are overworked, customers are losing their patience, and you risk losing business to competitors who can move faster. Sounds familiar?

The truth is, a packaging system can only move as fast as its slowest component, which is us – the human. Packaging automation drastically reduces human involvement in the process, thus increasing the speed of packaging process. Automating your packaging line means you can respond quicker to demand increases, thus vendors get their products on time, your employees can work more efficiently, and your consumers can get what they want. 

Automating your packaging process can lead to improved production speeds, thus helping you to keep up with an increased level of output. If you are expecting a large amount of growth over the coming year, or planning to expand your product line, then you should consider adding automated packaging equipment. 

The Packaging Team is Overwhelmed by Orders

Another indication of the need to automate is when you notice that your packaging team is overworked. Increased demand puts strain on your employees, which may lead to an increase in injuries, burnout, and stress due to the repetitive nature of their tasks and long working hours. Another important sign to notice is when you have a high number of employees requesting to resign. This can be a sign that the process is strenuous, thus harming the workers physically and mentally. 

An overwhelmed workforce leads to slow production, which can cause delayed orders, agitated customers, and lost sales. The company ends up producing less than its capacity – in other words, you are limiting your sales potential. If the slowdown lasts for only a short period, you may be able to resolve it by hiring more staff. However, if adding more employees does not resolve the problem, then you may want to consider automated packing.

When your unfulfilled orders continue to increase even when you have expanded your packaging team, the best solution is to invest in industrial packaging machines, such as bulk bag filling machine and open mouth bag filler. By introducing automated solutions, you can reduce the number of injuries and make your warehouses safer for workers.

Inconsistent Outputs & Unfulfilled Standards 

Humans can do a wonderful job in many things. However, simple, repetitive tasks in the packaging line can be an area in which we don’t particularly excel. Manual packaging processes can often lead to bottlenecks within a production process when human errors occur. Humans can be slow and make mistakes every once in a while, no matter how well-trained your team is. 

If you have standardised packaging requirements from clients, making sure that 100% of your outputs are adhering to the standards can be challenging. This is because inconsistencies and inaccuracies in your outputs frequently occurs when manual labour is involved, thus delivering unsatisfactory results. These simple errors can quickly add up to financial losses and create a ton of waste. 

An automated packaging process can help to eliminate this bottleneck since a machine can be designed to consistently keep up with the flow and requirements of the production line. With machinery automation & robotics, there will be less scope for packaging errors, which in turn leads to less downtime and bottlenecks. They can reduce or even completely eliminate packaging material waste, as well as ensuring that each of the outputs are equally sized and weighed.

Conclusion

If you have any doubts, work with a packaging professional who has experience in helping businesses improve their efficiency with packaging automation. At Aurora Process, we can help you to identify the potential for improvement, cost reduction, and increased productivity with industrial packaging systems. We are specialists in end-of-line process equipment who have worked closely with a variety of clients and industries – including grain & seed, food & dairy, growers, stock-feed, fertiliser, and cement manufacturers. Get in touch with us today and discover how you can improve your processing lines.

Global supply chains have always been vulnerable to shocks that affect the flow of goods and services – such as limitations to international business relations. However, the recent COVID-19 pandemic affected many supply-chain leaders in an unprecedented way – material shortages, drop in demand, worker shortage, are all felt by leaders across industries according to a recent survey by McKinsey. All of a sudden, companies have to restrict movement of people & goods, face border closures, as well as handling logistical constraints. At the same time, the demand for certain essential items surges to its highest level in the last few years. 

The pandemic has tested the industrial supply chain like never before – in fact, 94% of Fortune 1000 companies are seeing supply chain disruptions due to the pandemic. The labour-intensive manufacturing sector has been one of the hardest-hit. To mitigate the impact on business activities from COVID-19, players in the logistics, transport and supply chain industries had to adapt by transforming their operations. Here’s how the recent global pandemic has transformed the industrial supply chain.

Innovative Workforce Management Technologies

COVID-19 stressed the need for remote working & technology-driven industrial packaging systems to keep the team safe, while still delivering the resources needed to keep the business running. This crisis has accelerated the adoption of innovative workforce management technologies and practices among many companies. In fact, the pandemic is validating for those companies that already have a high degree of automation and remote access to critical business applications. These companies’ workforces are able to manage the systems from their own computers, tablets, even smartphones, thus enabling their business to run uninterrupted despite movement restrictions. While remote working is undoubtedly challenging to apply in the manufacturing sector, it is not entirely impossible.

With workplace safety and employee engagement more critical than ever, managers are adjusting workflows using workforce management technologies to accommodate a safe and properly-distanced environment. Remote monitoring solutions allows certain employees to still perform their task without having to physically be present on the factory floor. For example, a real-time AR-device showing production metrics by assembly lines, days, or shift, will allow plant managers to quickly oversee factory performance while maintaining a safe distance. 

Deeper Focus on Regional Supply Chains 

Many countries are looking inward for their supply-chain strategies, while multinational companies begin to consider minimising their outsourcing strategies to mitigate the risks of external disruptions due to different lockdown measures imposed by different countries. Governments of developed countries are increasingly addressing this matter – for instance, the Japanese government allocated US$2 billion to incentivise Japanese firms operating in other countries to relocate to Japan, a report by PwC stated. In addition, countries who produce essential supply of certain commodities seek to conserve these goods for their own consumption, restricting their export activities.

As a result, the global supply chains are becoming more regional in nature rather than international, moving closer to consumer markets. Strengthening regional supply chains and reshoring enables increased national security, local job creation, reduces vulnerability to external disruption, increases resilience, and fosters local development. This will create opportunities for local manufacturers  to replace the previously imported supply of goods by increasing their production output. To meet the new demand, one way for local manufacturers to increase the production quickly is by using industrial packaging equipment. 

Labor-Saving Technologies and Automation

Digital transformation in the manufacturing process was already going to happen in the near future, regardless of whether there was a pandemic to begin with; but Covid-19 has accelerated its adoption. The “new normal” restrictions with social distancing requirements demands a more efficient and agile manufacturing process in order to keep the supply chain running, which has made many businesses aware of the need for industrial industrial packaging systems.

As companies begin to restore operations and prepare a contingency plan to deal with future crises, digital technologies such as custom automation solutions will be on top of mind. Technological adoption in supply chain processes is critical to maintaining an effective supply chain industry, especially in the event of an unexpected supply shock. Players who are utilising machinery automation & robotics are in a better position to weather the storm, restoring their operations faster and further during a crisis compared to those who are behind in automation. 

If executed well, automation in the industrial supply chain can solve problems by increasing the efficiency of employees, increased warehouse savings, and faster production of goods. With industrial packaging equipment and robots, for example, manufacturers will be able to reduce the number of workers to embrace social distancing, while also increasing productivity & efficiency, lowering expenditures, and increasing production speed. 

Final Thoughts

All kinds of unprecedented challenges – pandemics, natural disasters, or labour shortage – can happen at any time; the question is whether we are prepared to face it. COVID-19 has exposed supply chains that are fragile to disruption, however it has also prompted the global industrial supply chain to change in a better way, such as embracing large-scale automation and moving to regional supply chains. The companies that deploy agile solutions that ensure visibility and the control will be the winners now and post-pandemic.

At Aurora Process, we are happy to assist you in unlocking your Process Potential, as we aim to make way for businesses to take advantage of everyday automation with confidence. We are specialists in end-of-line process equipment and industrial packaging machines, and we have worked closely with a variety of clients across the industrial supply-chain. Get in touch with us today and discover how you can improve your processing lines.

When it comes to buying industrial packaging equipment, there are hundreds of options available. Packaging machinery is a big investment decision for your business, you’ll want to take the time to research and invest due diligence into the process. But with so many options out there, how can you know if the machinery is suitable for your business?

In this article, we will discuss 5 Tips for Buying Packaging Equipment to assist you while considering the purchase of new machinery. 

Safety is Always First

When it comes to investing in new packaging machinery, it is always wise to start by considering the safety concerns surrounding packaging machinery. Reach out to a local vendor and request information about local safety standards for different types of machinery that you will be buying. For instance, risk assessment documentation is necessary to ensure the safety of your employees. By conducting a risk assessment, you can be sure that your packaging line is running at the optimum level of safety, thus your employees are working with the lowest possible risk.

When choosing a vendor for your packaging machinery, make sure that safety is of the highest priorities when it comes to their products. The safety of your employees and their environment must be a key focus of your industrial packaging systems. As time goes on, it is recommended to do an additional risk assessment regularly. This will be helpful, especially when adding new machinery or rearranging the current structure of your packaging line.

Get Familiar with the Different Types and Brands 

There are numerous types of packing machinery, coming from various different brands. Each brand offers different strengths and weaknesses. Researching a few different brand offerings for each piece of process equipment you are planning to invest in is a very important step. By doing so, you can be sure that you have chosen the right machine for your company’s budget, needs, and capabilities.

In addition, machines will need maintenance and service over time. Sometimes, it needs annual maintenance, while other machines may need semi-annual or even quarterly maintenance. It is very important to look into the machine’s design – does it consist largely of proprietary parts or easy to source parts? . To help you with this process, it is advised to work hand-in-hand with a packaging machinery expert or ask for a custom automation solution, so you can buy the equipment that suits your unique business needs.

Consider your Company’s Previous Experience and Goals

In order to understand the cost of your packaging machinery, you must first understand the particular needs of your company, the type of equipment you already have, and the additional options you want for your specific applications. If your company has worked with similar industrial packaging machines before and you are looking to upgrade, it might be best to learn from experience and work from there. Get your key people together, such as from machine maintenance, cleaning, operation, and safety. Listen to their suggestions on how we can improve the existing packaging equipment. This meeting will tell you exactly what you currently have, and how you can improve on the new equipment.

More importantly, assess your business and determine your objectives before you start contacting vendors. What is your main goal with the new machine? Is it simply to increase productivity, or is the machine part of a long-term plan to enter a new market? What are the production requirements for the smallest and largest products? By gathering this important information beforehand, it will be much easier to find the right automated packaging equipment that satisfies your demand.

Cost-Benefit Analysis

It is only logical to perform a cost-benefit analysis before making a big decision. When it comes to the cost of your packaging equipment, you need to weigh your options wisely. For instance, you have the option to either buy new, used, or refurbished equipment. Each of these three options come with very different price tags, and have significantly different strengths and weaknesses. Moreover, do not ignore the cost of regular maintenance and repairs in the future. A regular maintenance plan will greatly reduce downtime and the risk of irreparable damage.

While it is true that packaging machinery comes with a significant up-front financial cost, the benefits they bring are often worth their price tag. If the speed of getting your product to market is an important dynamic for your business, then time becomes a huge concern. Packaging machinery allows you to package more products per hour than physical labor and do so more efficiently, thus it offers greater benefits for you when compared to manual workers. Packaging equipment is more reliable in terms of the quality of outputs it produces, as it doesn’t get sick, tired, sleepy, or commit any other human errors.

Other Important Considerations for Buying Packaging Equipment

Another important consideration is whether the machine can grant you greater flexibility with tool-less changeover. A Tool-less Changeover means that the machine can switch quickly between different pack sizes, different grids and different tasks, without the need of screwdrivers, wrenches, or other tools. This is a must for companies that produce a variety of products, since it reduces downtime associated with product changeover and thus improves packaging line efficiency.

Each packaging equipment range has its own unique character. Whether you prefer robotic packaging systems or manual ones, use these five tips to guide you in your purchasing decisions and to help ensure that your industrial packaging equipment brings you only the best results. Working with a packaging automation expert from the start will save you money and time, and it certainly will help you avoid many unprecedented pitfalls.

At Aurora Process, we are here to make packaging automation easier for you, no matter what your business does. Unlock your Packaging Potential today with us. 

Nowadays, industrial packaging systems seem to be more high-tech than ever before. The technology driving automation in End-of-Line process equipment is constantly evolving, and for good reason. It helps companies to meet the markets’ increasingly volatile demand and solve labour shortage issues, just to name a few. In fact, automation is making robots a more integral component because of the contributions they’re making to the overall efficiency and productivity of today’s processing and packaging lines.

Automating a processing line may sound daunting to some, however with its numerous benefits, including improved efficiency and decreased costs, automation may be the right choice. How can your End-of-Line benefit from automation & robotics? Let’s find out together.

Solve the Issue of Rising Demand and Labour Shortage 

The growth and prosperity of the middle class population will cause the demand of mass production of food to grow exponentially. However, the supply of blue-collar workers is shrinking in many developed countries, as one article has noted. When labour shortages arise, food processing companies may struggle to keep up with the rising demand. This has been a constant issue, even before the pandemic and the significant impact it brought, such as social distancing in the workplace and the supply-chain crisis for nonperishable foods as people started to buy in bulk.

The food production industry has typically been labour-intensive, especially the end-of-line packing. It’s quite common to see rows of people at the end of the line, inspecting products and packing it into cartons and boxes. This calls for efficient and innovative custom automation solutions to satisfy the increasing demand, while also finding ways to improve productivity and reduce manual labour. 

Reduce Cost and Increase Efficiency

There is no doubt that automating your processes can greatly enhance your productivity and efficiency, leading to a better ROI. To illustrate, let’s compare the associated cost of a manual 1500-box operation with using just one machine to automate the task of setting up boxes. With manual labour, you need 3 workers, working at 3 hours/day each. Say if their hourly rate is $18/hour, and they work 5 days a week. This translates to $38,880 annual cost. 

Compare this cost to installing a case erector machine or other industrial packaging machines, which can be easily integrated into your production line. It needs 1.25 hours to yield the same output, and it can be programmed to pre-tape the bottoms of boxes at the same time. In addition, these machines can easily be enhanced to produce 3 to 4 times its normal capacity, should the need arise. When compared with the cost of labor required to complete the same task, it becomes clear that automation & robotics offer distinct benefits with solid ROI numbers.

Enhanced Safety and Reduces Errors

The risk of injuries are relatively high for blue-collar workers in a manufacturing environment. Back injuries from manually wrapping pallet loads, carpal tunnel syndrome from repetitive motion during package assembly, and injuries due to the lack of safety guards on older equipment, are all commonly found among them over an extended period of manual labour. While training the people who will be using the machinery should also be an important part of the equation, this problem can be addressed with updated packaging equipment. By ensuring that the solution is matched to the specific requirements of a given line, custom automation solutions can deliver safety for your employees.

Furthermore, letting automated packaging equipment perform end-of-line processes reduces the room for human errors. In food industries, package seal integrity, and the accuracy of product inspection, checkweighing, and labeling is highly crucial to comply with regulations. A simple human error could quickly turn into a product recall announcement and PR disaster – a true nightmare scenario for brand managers.

Businesses of all shapes and sizes can take advantage of the labor, safety, and cost-saving benefits that result from automated systems engineering, thus remaining competitive and gaining market share After reading this article, pay close attention to your End-of-Line processes – does there seem to be a bottleneck around one station? Is there a concentration of workers idling around? These could be opportunities where automated packaging could help you improve your throughput. Proactively check your entire packaging operation today for any potential safety hazards and eliminate the issue by automating your processes. 

At Aurora Process, we are happy to assist you in unlocking your Process Potential, as we aim to give way for businesses to take advantage of everyday automation with confidence. We are specialists in end-of-line process equipment, such as bag filling machine and pallet automation systems. We have worked closely with a variety of clients and industries – including grain & seed, food & dairy, growers, stock-feed, fertiliser, and cement manufacturers. Get in touch with us today and discover how you can improve your processing lines.