Second Hand Packaging Machines: A Sustainable Choice

Rebuilding second-hand packaging machines is a cost-effective and sustainable alternative to purchasing new equipment. It not only extends the lifespan of existing machinery but also incorporates modern technological advancements. This approach is ideal for businesses seeking to enhance operational efficiency and reduce environmental impact while managing budget constraints effectively. Upcycling is acclaimed as a method to enhance the quality of materials and products within value chains (Fletcher and Grose, 2012) and to address the prevailing trends of planned and premature obsolescence (Sung, 2017).

Environmental Benefits of Up-cycling Machinery

1. 1. Reduced Waste: Upgrading machinery contributes significantly to waste minimisation. It prolongs the life of existing machines, thereby cutting down on industrial waste and lessening the demand for new raw materials.
   2. Energy Efficiency: One of the paramount benefits of upgrading second hand packaging machines is enhanced energy efficiency. Older machines, when upgraded, can operate more efficiently, thus reducing energy consumption and carbon emissions. New servomotors coupled with advanced planetary gear boxes require less power to achieve the same torque outputs as older generation machinery. Servo motors exhibit exceptional efficiency, exceeding 90%. This means that a significant portion of the electrical energy provided is efficiently transformed into mechanical power.
   3. Sustainable Practice: Embracing the repurposing of machinery advocates for a circular economy. This model emphasises keeping resources in use for as long as possible, extracting their maximum value, and then recovering and regenerating products at the end of their service life.

Economic Advantages

1. Cost-Effectiveness: Often, upgrading second-hand packaging machinery is more cost-effective than investing in new equipment. It’s crucial to consider the hidden costs associated with new purchases, such as installation, training, and integration into existing systems.
2. Increased Productivity: Machinery upgrades can lead to enhanced efficiency. This increase in productivity can be achieved without the substantial investment required in new equipment.
3. Longer Lifespan: Proper maintenance and timely upgrades can significantly extend the life of packaging machinery. This leads to a better return on investment, as the machinery continues to serve beyond its expected lifespan.

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Technological Improvements on Up-cycled Second-Hand Packaging Machinery

1. Modernisation: Upgrading old machinery can involve integrating modern technology. This modernisation improves the functionality and capabilities of the machinery, keeping it relevant in a rapidly evolving technological landscape.
2. Customisation: You can customize second-hand packaging machines to meet specific operational needs. This level of customisation is often not feasible with new, off-the-shelf equipment. Features such as no product no bag, print registration or an auto-feeding options can be added. We can also integrate new in line machinery both upstream and downstream.
3. Compliance: Bringing older machinery up to date ensures compliance with current safety and regulatory standards. This is crucial, especially in industries where regulations are stringent and constantly evolving. New guards and safety systems can prevent staff the likelihood of staff injury.

Case Studies and Examples

Bakery :

At Record Packaging, a bakery company presented us with a challenge regarding their existing packaging machine. They wanted a new line, but the lack of capital expenditure approval hindered them. In response, we offered a strategic solution – a substantial upgrade to their old wrapper, rather than purchasing a new one. This enhancement involved implementing a new side feeding infeed system and a sophisticated electronic Multidrive system incorporating Siemens components. Despite navigating supply chain difficulties, our team efficiently adapted our designs for prompt completion.

This upgrade dramatically improved the machine’s efficiency, leading to an approximate 40% boost in productivity and a 30% reduction in operating costs. Crucially, it eliminated the need for two employees to manually feed the line, thereby freeing them up to focus on other pressing areas of the business. The transformation, which included a full repaint and an overhaul of the transmission and drive systems, essentially converted their existing machinery into a new, more efficient line at a substantially lower cost. These significant improvements mean this bakery will see a return on investment in just one year, primarily driven by the considerable savings in labour costs and enhanced operational efficiency.

What Repurposing Second-Hand Packaging Machines Involves

1. Assessment: Evaluate the existing machine’s condition, capabilities, and potential for repurposing. This includes checking for wear and tear, assessing mechanical and electrical systems, and identifying areas that require upgrades.
2. Planning: Develop a detailed plan outlining the scope of work. This includes deciding on the upgrades needed, sourcing parts, and determining the extent of mechanical and technological enhancements.
3. Design Modifications (If Required): Create design modifications to incorporate new features or improve existing ones. This involves reengineering certain parts and also integrating new technologies.
4. Disassembly: Carefully dismantle the machine, especially parts that need refurbishing or replacing.
5. Cleaning and Repairing: Clean all components thoroughly. Repair or refurbish parts that you will reuse to ensure they remain in optimal condition.
6. Upgrading and Rebuilding: Implement the planned upgrades, which may include installing new electrical systems, mechanical parts, software updates, or other technological enhancements.
7. Reassembly: Reassemble the machine, incorporating the upgraded and refurbished components. Ensure that everything is aligned and also fitted correctly.
8. Quality Assurance and Compliance Check: Perform a quality assurance check to ensure the upgraded machine meets all necessary standards and compliances.
9. Training and Documentation: Provide training to the operators on the new features and functionalities. Update the machine’s documentation to reflect the changes made during the repurposing process.
10. Installation and Commissioning: Finally, install the machine back into its operational setting and perform a final commissioning to ensure it’s fully functional and ready for production

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