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Cost Saving Techniques for Packaging Lines

Updated: Jan 20, 2021

In a world of fast-paced dynamics, companies are fighting tooth and nail to emerge as ‘the number 1 choice’ of consumers. Quality, Price, and Unique features are of course important differentiating factors. Adding to this, the packaging of a product is increasingly becoming an integral part of customer expectations as well as a brand’s USP. Firms can intelligently leverage their packaging line procedures to attract more and more customers and boost customer loyalty.

“Packaging of a product is its theater, make it tell a great story.”

What is a Packaging Line?

When ketchup is transferred to bottles for ultimate sale, when medicines are packed in tamper-proof sachets, when ready-to-eat food packets are sealed in foil, when milk is measured and packed in tetra packs, that is packaging line in action.

A packaging line essentially bridges the gap between a raw product and a sell-able product. It is a sequence of activities (such as filling, capping, labeling, etc.) that products undergo, to become market ready. These processes are the fundamentals that ultimately shape the final package. Along with protecting the product, they give the product its external look and feel. Due to its critical role in a product's life cycle, it is crucial to understand that the efficiency of a packaging line directly impacts the cost of packaging. The higher the inefficiencies in the packaging line, the higher are the costs. And this cost eventually reflects on the ultimate price of a product when sold to consumers.

Adopting and implementing a cost control program is sure to help in improving the efficiency and profitability of packaging lines. We, at VYNXPACK, specialize in optimizing packing line efficiencies and performance.

Here are 6 simple tips that can help you identify inefficiencies in your packaging line and in turn, save on overhead expenses:

1. Manual v/s Automatic

Automating mundane and routine tasks not only reduces costs in terms of saved labour, but also eliminates chances of human error (which are almost always higher than mechanical errors). Manual operations limit the output and increase the risk of defects. On the other hand, employing a limited workforce by incorporating automation not only increases efficiency but also helps in reducing expenses. Factors such as the structure of your production floor, nature of the product and allocated budget, must be kept in mind while making the switch from manually handled procedures to automated systems. Our experts are trained in identifying the best mix between manual and automated work in packaging lines.

If you are a company that regularly deals in mass production and hectic delivery schedules, adopting fully automatic packaging lines shall significantly boost performance and reduce costs. Manual packaging systems or semi-automatic lines can be used for smaller orders and companies dealing in highly customized orders.

2. Periodically Review your Packaging Material

Advancements in technology, accompanied by improved connectivity, enables manufacturers to access a wide variety of packaging options irrespective of geographical locations. From corrugated trays, shrink films or environment-friendly materials to reusable ones, all can be procured from selected suppliers. Hence, an ideal packaging choice requires careful inspection of the current material together with the type of product.

Companies can identify wastage, by measuring the amount of material needed versus the amount being used. An audit by an industry expert may also reveal areas of abnormal wastage. Administrators can accordingly alter the material length to make the packaging simpler and faster.

3. Manage Machine Time

Check for slow points that are causing a delay in the packaging line. These points are known as bottlenecks. Bottlenecks can be reduced either by decreasing the level of input or by improving the efficiency of the packaging line. By observing the time loss caused by these bottlenecks, firms can suitably design machine schedules and take necessary corrective measures.

4. Maintenance Checks

Regular or at least occasional checks on machines should be done to ensure that they are in good working condition. These planned activities, such as checking and supplementing machine parts, greasing of equipment, etc. are known as ‘preventive maintenance’. Their key objective is to mitigate the risk of failure associated with breakdowns. If such precautions are neglected, your company will end up spending more time and money on repairs rather than packaging. Regular check-ups are always recommended to prevent massive breakdowns.

5. Trained Workforce

It is accurately said, “The right people are the firm's most important asset.”

Be it a manual, automatic or semi-automatic packaging line, they all require a trained and skilled workforce. Proper training of workers constitutes an integral part of ensuring effective packaging. Skilled workers will handle the equipment responsibly and ensure a reduction in wastage. Technological knowledge and skill make the workforce better equipped to handle problems arising on the packaging line.

6. Shutdown

Before leaving for the day, check if the machines and equipment, along with other devices on the shop-floor, have been entirely switched off. This may sound obvious, but many companies have suffered because of machines not being shut down. They’ve lost out on downtime and overburdened their costs only because of preventable lapses such as these. Proper maintenance and downtime of packaging equipment helps in keeping costs low.

In Conclusion

Attractive packaging need not be a burden to your capital. In fact, it is a tool that can represent what your brand stands for. A tool that can ensure repeated purchases. A tool that makes your product stand out in a world of cutthroat competition. All of this can be implemented well within the allocated budget and still simultaneously improve profits. The money saved by implementing these techniques can be further reinvested on improvisations and upgrading of the packaging line.

If you’re interested in designing / redesigning your packaging line, or even do an audit to boost efficiencies, get in touch with us by writing to us at

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