5 Common Packaging Line Mistakes and How to Avoid Them

An efficient packaging line is the engine of a successful production operation. When it’s running smoothly, products move seamlessly from the production floor to the customer. However, even small errors can lead to costly downtime, product waste, and a hit to your bottom line. At Record Packaging Systems, we’ve seen it all, and we’re here to help you identify and correct the most common packaging line mistakes.

Mistake #1: Mismatching Materials and Machinery

One of the most frequent errors we encounter is using the wrong packaging materials for a specific machine. A flow wrapper, for example, is engineered for a certain range of film types and thicknesses. Using a film that is too thin, too thick, or has the wrong properties can lead to poor seals, machine jams, and excessive material waste.

How to avoid it: Always consult with your machine supplier before changing packaging materials. A simple conversation can prevent a costly problem. We work closely with our clients to test new materials and ensure they are compatible with our machinery, guaranteeing smooth and reliable operation.

Mistake #2: Neglecting Preventive Maintenance

It’s tempting to run a machine to its breaking point, but this “run-to-fail” mentality is a recipe for disaster. Waiting for a critical component to fail before scheduling a repair can result in sudden, unplanned downtime that halts your entire production.

Andrew Murphy, Operations Director, emphasizes the importance of a proactive approach: “The biggest mistake a company can make is underestimating the value of a solid preventive maintenance plan. Our machines are built for durability, but like any high-performance equipment, they require regular care. Simple tasks like lubrication, calibration, and timely replacement of wear parts can drastically extend the life of your machine and, more importantly, prevent a complete line shutdown that costs far more than the maintenance itself.”

Mistake #3: Buying a “One-Size-Fits-All” Solution

Trying to save money by purchasing a generic machine that isn’t perfectly suited for your product is a common pitfall. While a machine might work initially, it will likely struggle with consistency, speed, and efficiency in the long run.

Robert Murphy, Sales Director, advises clients to think critically about their long-term needs: “My role is to ensure our customers get the right machine for their specific needs, not just what’s available. The mistake I see most often is businesses trying to force a generic machine to do a specialized job. We always advise clients to consider their product’s dimensions, weight, and fragility, as well as their production goals. A machine that is purpose-built or expertly configured for your application will always deliver better performance, greater reliability, and a far better return on your investment over time.”

Mistake #4: Skipping Proper Operator Training

The most advanced packaging machine is only as good as the person operating it. A lack of proper training can lead to inefficient operation, frequent errors, and even safety hazards. An untrained operator might not know how to perform a quick changeover, troubleshoot a common issue, or identify a problem before it becomes a major fault.

How to avoid it: Invest in comprehensive training for your staff. Record Packaging Systems provides detailed training during installation to ensure your team is confident and competent. Proper training empowers your operators, turning them into a valuable asset in maintaining line efficiency and product quality.

Mistake #5: Underestimating the Power of Line Integration

A packaging line is more than just a collection of individual machines. It’s an ecosystem where each component must work in harmony. Failure to consider how a new machine integrates with existing conveyors, weighers, or other equipment can lead to bottlenecks and workflow disruptions.

How to avoid it: Plan your packaging line as a single, cohesive unit. When you partner with us, we don’t just sell you a machine; we help you find a solution that fits seamlessly into your existing production environment. Our experts can advise on line layout and configuration to ensure a smooth, end-to-end process.

By being proactive and avoiding these common pitfalls, you can transform your packaging line from a potential source of headaches into a reliable engine for growth. At Record Packaging Systems, we’re committed to providing not just high-quality machines, but also the expertise and support you need to succeed.