How to Balance Budget and Innovation When Choosing a Case Packer

Many food manufacturers and co-packers find balancing cost constraints and the push for innovation challenging. A decision on case packing could involve automating primarily manual processes or upgrading an existing case packing system to one that meets their complex needs. Automation has made it possible to improve efficiency, increase productivity, and minimize downtime, but budget considerations must also be taken into account to determine the right solution. 

We’ll explore these considerations through a practical lens and discuss ways to measure automation's ROI. We’ll also discuss how a partnership with BPA can help you determine when robotics and other premium features may be necessary and cost-efficient to help you stay competitive in your industry. 

Measuring the ROI of Automated Case Packers

One of the first things we explain to our customers is that investing in a case packing solution is not just about the upfront cost. The return on investment (ROI) is a critical factor, encompassing tangible, non-tangible, and hidden benefits that can dramatically impact your bottom line. 

• Tangible ROI: Automation directly reduces labor costs by minimizing the reliance on manual operators. Additionally, automated systems decrease downtime and ensure consistent and many times increased throughput, boosting overall production efficiency.
• Non-Tangible ROI: A reliable automated system reduces training and turnover costs. By eliminating repetitive tasks, manufacturers can create a safer and more engaging work environment, which improves employee retention.
• Hidden ROI: Automation's benefits extend beyond the plant floor. Optimized case sizes and packing styles reduce corrugate waste and shipping costs for ongoing savings. 

Understanding ROI in these terms allows manufacturers to see automation as an investment, not an expense. By accounting for these factors, manufacturers can make informed decisions that align with both short- and long-term goals.

Understanding the Costs of Case Packing

Initial costs and budget should still be considered when deciding on automation. Sometimes, the need won’t justify the costs or may only require a slight push toward automation. For example, manual processes may be suitable for low-volume or short runs. A semi-automatic solution can offer some automation benefits while keeping manual operations in place.

However, once rate or precision requirements increase, the need for an automated system also increases. Automated case packers can handle a wide range of products, packing patterns, and case sizes to meet production goals. For many applications with consistent orientation, a Gantry-style case packer will suffice, providing horizontal and vertical packing with quick changeover capabilities. For more complex runs, though, sophisticated robotics will be needed to meet throughput demands.

These systems are more expensive upfront but provide unmatched efficiency and precision for demanding applications.  They also come with fewer changeparts between recipes. As experts in secondary packaging, we have a wide range of modular components to ensure the best solution based on your specific production demands and necessary costs. We can also take ownership of conveyance, collation, and palletization to ensure optimal flow and conditioning throughout production.

When Should Manufacturers Consider Robotics?

Robotics are crucial for manufacturers dealing with high-speed lines or complex product requirements. However, the costs of robotics and vision systems can add up fast, so evaluating your needs against what you can spend upfront is essential. 

Previously, in our blog on AI technology, we discussed how manufacturers should start with low-hanging fruit and avoid buzzwords or trends that may not align with their actual needs and goals. Robotics and complex vision systems aren’t necessary for every solution, but they are invaluable for specific applications:

• High Production Rates: For lines exceeding 140 products per minute, traditional manual and some automated systems struggle to keep up. Robotics can handle these speeds while maintaining accuracy and minimizing downtime. 
• Random Product Orientation: Products with inconsistent orientations on conveyors introduce unique challenges. For example, if a bagger outputs products in random orientations, a simple photo-eye sensor won’t work. A vision-guided robotic solution becomes necessary, as it can identify and handle products regardless of their position.
• Small Facility Footprint: Compact facilities and poor layouts limit space for many manual packers or additional machinery, making robotics essential for streamlining workflows. Automated systems and robotics, specifically, optimize packing within tight spaces and negate the need for sprawling setups that minimize floor space and productivity. 

Robotics may represent a higher upfront investment, but the long-term benefits far outweigh the initial cost for applications with demanding speed and orientation requirements or limited space.

How BPA Can Help You Evaluate Your Needs and Budget

One of the advantages of partnering with BPA for your case packing needs is our process. We can help you distinguish between essential needs and advanced wants to find a tailored solution to increase productivity, efficiency, and flexibility. 

Our decades of experience in the secondary packaging industry have enabled us to deliver unique solutions with unparalleled craftsmanship and operability. Our case packers are easy to maintain and operate and are supported by aftermarket services that extend equipment life. These benefits help offset the initial cost and boost ROI.

If you’re considering vision-guided robotics or custom features for scaling or complex applications, we can help assess their necessity. By evaluating your layout, production needs, labor turnover, and budget, we prioritize investments to maximize value. ROI and other metrics will help guide our decisions to allocate resources effectively.

In our consultation, we can also highlight how quickly automation can deliver benefits now and in the long term. Inaction has its own price. Delaying needed investments can lead to inefficiencies, higher labor costs, and missed opportunities. Our sales engineers will help you weigh your options to deliver the most value on your investment at a comfortable price. 

Wrapping Up

Henry Ford once said, “If you need a machine and don't buy it, then you will ultimately find that you have paid for it and don't have it.” Yet, balancing budget and innovation in case packing is no small feat and can often lead to indecision or making the wrong choice on a system that doesn’t meet your needs or has too many bells and whistles to justify the cost. 

This is where a partnership with BPA can pay significant dividends on your investment. By focusing on long-term value and alignment with your processes, products, and packaging, we can help you strike the perfect balance between budget and innovation to remain competitive in your industry. Contact us today to start the conversation.