Pet food manufacturers are moving towards stand-up pouches for various products, including wet cat food, dog treats, and bird seeds. These pouches offer some advantages from traditional packaging like retort cans and larger bags. Yet, their unique characteristics also present a complex set of challenges for secondary packaging automation, especially for high-speed vertical case packing and packing low-count cases.
As a leader in secondary packaging solutions in the pet food industry, we have worked with a number of pet food manufacturers to optimize their operations and address challenges pouches may introduce to secondary packaging lines. We’ll examine some of these inherent challenges and how our advanced automation solutions can help manufacturers overcome logistics obstacles, reduce costs, and boost productivity.
Pouches align well with today’s consumer preferences. They’re user-friendly, easy to open and reseal without tools, and support portion control and on-the-go feeding. Their high-barrier, sealed film construction also offers strong protection against moisture, oxygen, and contaminants, helping to preserve freshness across multiple uses.
Manufacturers looking for sustainable packaging may opt for pouches as they generally use less materials and generate less waste than cans and bags. The industry is also seeing a move towards mono-materials that could help improve recyclability. Still, there are complex challenges in secondary packaging automation that manufacturers must consider in this industry-wide shift towards pouches, including the pouch’s shape, weight, and firmness.
Irregular Shape and Design: Unlike rigid containers, flexible pouches lack a consistent, fixed shape. Their form can shift depending on the fill level, product movement, and how they're handled, posing challenges for automation systems that rely on precise, repeatable motions. Unique pouch formats, such as triangular designs, may demand specific rotational handling for optimal nesting,
Product Slippage: The smooth, often somewhat slippery surface of many pouch materials can lead to pouches sliding on conveyors, making precise placement difficult. Pouches are lightweight and nearly impossible to accumulate. They require the entire system to run in unison for optimal efficiency and uptime. Their thin edge seals can also easily catch or snag during processing.
While pouches offer convenience and sustainability, they can be significantly more expensive than rigid containers. To offset these costs, manufacturers often seek to consolidate SKUs and minimize changeovers to boost productivity. However, the handling challenges we described above lead to greater reliance on manual labor in secondary packaging, driving up operational expenses.
Despite these issues, advancements in automation are making it increasingly feasible to efficiently handle pet food pouches and pack them for distribution. As a secondary packaging automation partner for pet food manufacturers, we focus on comprehensive, integrated systems that address the unique requirements of pouch handling.
We leverage sophisticated robotic systems, like our Spider 300v, with advanced vision capabilities that allow the case loading system to "see" the pouches, adjust their grip based on subtle variations in orientation or shape, and precisely place them.
Additionally, vision systems can inspect pouches for sealing, weight, and orientation for quality control, allowing only proper products to be packed.
Many pet food pouches are packed vertically because of their stand-up design and to enhance shelf appeal. Traditionally, manual packers have been used for packing lightweight pouches into cases, but manufacturers are looking at ways to automate these processes if possible to reduce costs and increase consistency.
BPA machines suitable for vertical packing pouches include our Gantry 300 Swing, a case packer built for flexibility that can handle a large variety of case packing options. Our Collator 200 semi automatic packing equipment can also be used to stand up pouches vertically to assist hand packers and increase production speeds.
We also specialize in lower count cases, which must be automated if at all possible to account for the large box count and required orientation.
We can integrate custom conveyance systems that gently guide and support pouches, preventing them from toppling or shifting. Our systems can include specialized belts, lane dividers, and vibratory feeders that ensure consistent product flow and presentation to the robotic cell or case packer before the pouches are packed.
Pouches are notoriously difficult to automate in secondary packaging operations, but having the right solutions provider can help pet food manufacturers identify opportunities for automation. At BPA, we focus on learning about your unique needs to determine the right system for your line and budget. Our process ensures better overall productivity and prevents issues that could reflect poorly on the machinery
By implementing BPA's specialized solutions, pet food manufacturers can significantly improve productivity, as demonstrated by a customer who increased volume by 30-40% and reduced their reliance on hand packers after installing an automated system. We strive to achieve results like this every time through our personalized approach.
The shift towards smaller pouches in the pet food industry has made feeding our furry loved ones more convenient and healthy. Yet, manufacturers face higher packaging and labor costs as pouches are typically irregularly-shaped and difficult to automate for secondary packaging operations. We will listen to you and devise a tailored solution that meets your unique needs. Partner with BPA to drive efficiency, reduce manual labor, and meet consumer expectations with our secondary packaging solutions for the pet food industry.