Packed With Expertise Blog

December 30, 2021

<p>Cost calculation is an important early step to determining potential <span style="text-decoration: underline">return on investment (ROI)^{Return on investment (ROI) is the ratio of the profit of an investment to the cost of that investment.}</span>. When investing in packaging machinery, however, calculating the initial purchase price alone is not enough. To properly inform your investment decisions, it’s important to understand the total cost of ownership (TCO). In this post, we’ll define TCO for packaging equipment, provide a list of factors you should consider during cost calculation, and share tips for how you can keep costs low.</p><h2>What is TCO and why does it matter?</h2><p>Total cost of ownership (TCO) refers to the long-term costs associated with owning and maintaining a packaging line or machine throughout its entire lifecycle. In addition to your initial capital investment, you will incur costs associated with the purchasing process, plant operations, machine maintenance, technical support, and more. By accounting for all these costs, you can accurately calculate the total cost of owning the equipment and subsequently, better predict your ROI.</p><h3>Common Packaging Equipment Cost Factors</h3><p>When you’re purchasing new packaging equipment, there are several project-specific factors to consider. Maybe you’re relaunching your product with a more sustainable package, and you need to account for a longer testing period to ensure the equipment is compatible with the package. Or maybe you're opening a new production plant and you need to assess your requirements for on-site utilities. While every project comes with its own unique cost factors, most costs can be simplified into three categories – capital costs, operational costs, and maintenance costs. We'll summarize each category below, but for a more comprehensive explanation&nbsp;<a href="https://go.bwpackagingsystems.com/tco-calculation-guide" target="_blank" data-sf-ec-immutable="">download the free TCO calculation guide</a>.&nbsp;</p><p><a href="https://go.bwpackagingsystems.com/tco-calculation-guide" target="_blank" data-sf-ec-immutable="" class="button green">Download the Guide</a></p><h2>What are capital costs?</h2><p>Capital costs are the initial expenses that you will incur upfront with the purchase of your packaging equipment. These costs are typically one-time expenses that can be calculated by considering factors such as:</p><ul><li>Equipment design</li><li>Permits, certifications, acceptance testing</li><li>Shipping and installation</li><li><span style="text-decoration: underline">Equipment validation^{Equipment validation encompasses the final tasks that are required for an original equipment manufacturer (OEM) to hand off newly purchased equipment to a consumer packaged goods (CPG) company. Equipment validation tasks include, for example, ensuring ensuring installed equipment meets quality and throughput requirements.}</span></li></ul><h3>2 Ways to Lower Capital Costs</h3><h4>Take a consultative approach during contract negotiations</h4><p>Im­posing too many strict demands (i.e., tight time constraints, total control over <span style="text-decoration: underline">OEM^{In the packaging industry, an original equipment manufacturer (OEM) is the company which manufactures the machinery used to facilitate the packaging process.}</span> selection, etc.) will drive up the purchase price. On the other hand, taking on responsibility in-house for tasks you’re not set up to handle can also put the project at risk. The best way to navigate this conundrum is finding your ideal balance between cost and risk. This requires looking inward at the depth and strengths of your in-house resources and asking yourself a series of questions.</p><ul><li>Who should be responsible for each task?</li><li>What risks are associated with owning those tasks in-house?</li><li>What assurances are granted by contracting the integrator to do them?</li></ul><p>These questions will help you make cost-effective decisions during contract negotiations.</p><h4>Maximize SKU variability with flexible packaging solutions</h4><p>Sometimes, considering equipment speed and capability alone is not enough. It’s also important to evaluate the need to interchange between these factors, especially if you are a <span style="text-decoration: underline">co-packer^{A co-packer (or contract packager) is a company that packages and/or labels goods for another company or brand owner.}</span>. Investing in a flexible packaging solution that is easily configurable and designed for quick <span style="text-decoration: underline">changeovers^{A changeover is the transition time from running one item (or SKU) in a manufacturing process to another.&nbsp; Some machines change over using the “recipe” system, where the parameters for different products are stored and then drawn into the machine parameter database. This allows a packaging machine to run different weights, sizes, and volumes with precision.}</span> will allow you to produce multiple SKUs as quickly as possible on the same machine. By evaluating the need for flexibility during the equipment design phase, you’ll reduce your need for future capital investments.</p><h2>What are operational costs?</h2><p>Operational costs are the ongoing expenses that you will incur to run your packaging equipment. These costs recur throughout the life of the equipment and are calculated by considering factors including:</p><ul><li>Staff training</li><li>Automation and labor requirements</li><li>Utilities</li></ul><h3>2 Ways to Lower Operational Costs</h3><h4>Keep superb training and troubleshooting resources</h4><p>Your packaging equipment supplier should provide you with an operator manual and step-by-step training documents for future employee onboarding. This will mitigate some of the recurring costs of training. Some OEMs also include operator training resources via the <span style="text-decoration: underline">human-machine interface (HMI)^{A human-machine interface (HMI) is the dashboard through which an operator interacts with packaging systems or equipment. Modern HMIs can offer operator training resources, provide preventative maintenance reminders, assist in troubleshooting machine malfunctions, and much more.}</span>. This can include video tutorials and on-demand training guides to make setup and operations simple. Including these training resources directly within your packaging solution allows your operators to always have access to the most up-to-date training and troubleshooting resources available.</p><h4>Create efficient changeovers with packaging automation</h4><p>Whether you’re a private label manufacturer or a co-packer, maximizing your production time is a priority. As you evaluate machines for your packaging line, look for options that will automate processes that would otherwise require a hefty investment in manual change­overs. Automated changeovers are popular because they’re easy and cost-efficient. Once you program the recipe, there isn’t much more to the changeover than selecting the right recipe – the automated system does the rest of the changeover for you, reducing operator overhead and the opportunity for errors to occur.</p><h2>What are maintenance and support costs?</h2><p>Maintenance and support costs are the ongoing expenses associated with keeping machinery in working order, troubleshooting, and resolving unexpected disruptions. These costs can be trickier to manage than capital and operational costs because it’s not always clear when maintenance and support will be required. However, you can mitigate unexpected costs through careful consideration of:</p><ul><li>Documentation</li><li>Parts Lists (Spare and Wear)</li><li>Aftermarket Support</li></ul><h3>2 Ways to Lower Maintenance and Support Costs</h3><h4>Stick to the maintenance schedule</h4><p>Abiding by the supplier-recommended maintenance schedule is the easiest (but most important) way to keep your maintenance costs low. Completing tasks such as cleaning, lubricating, and replacing worn out parts within the recommended time frame results in fewer breakdowns, less downtime and lower emergency maintenance costs, as well as increased safety for your machine operators.</p><h4>Include a parts and service agreement in your contract</h4><p>Parts and service agreements can reduce your maintenance costs by giving you fast access to wear parts and ensuring OEM availability when you need emergency technical support. By working with your supplier to create a package that supports your long-term maintenance needs and your overall investment and production strategy, you can better plan for the costs ahead and mitigate any unplanned expenses.</p><h2>The Comprehensive Guide to Calculating Packaging Equipment TCO</h2><p>Did you find this content useful? If so, check out our comprehensive guide to calculating packaging equipment TCO. It provides breakdowns for each of the cost factors mentioned above, additional tips for keeping costs low, and a list of proven packaging solutions to consider for your next project.</p><p><a href="https://go.bwpackagingsystems.com/tco-calculation-guide" target="_blank" data-sf-ec-immutable="" class="button green">Download the Guide</a></p>

October 28, 2021

<p><strong>Carol O'Neill, Group President of Packaging for Barry-Wehmiller, leads efforts to enhance the alignment and capabilities of the five divisions that make up the BW Packaging Systems platform. This content contains excerpts from her interview with Jennifer Mackey, guest host of the&nbsp;</strong><a href="https://www.slu.edu/business/centers/boeing-institute/podcast/index.php" data-sf-ec-immutable=""><strong>SLU International Business Now podcast</strong></a><strong>&nbsp;on October 4, 2021.</strong></p><p>As you may know, sustainability is a topic that is very near and dear to my heart. So, when I was asked to speak about sustainability efforts in global business on the SLU International Business Now podcast, I welcomed the opportunity to share some learnings and perspectives I’ve gained over the years.</p><p>I can remember 20 years ago working in the packaging industry and even then, saying “we need to have an eco-friendly packaging strategy.” People said “eh, you know this is a fad. Environmental consciousness comes and goes.” I remember saying, “Maybe it’s a fad, but wouldn’t we want to be part of coming up with a solution so that it didn’t have to be a fad?”</p><p>Today, sustainability is here to stay. It is not a fad. The world has become much more aware of humans’ impact on our environment. As we look ahead, I think we will be – and frankly should be – challenged to use our creativity and our innovation capabilities to work in a way that conserves our precious resources and that minimizes our impact on the world.</p><h2>BW Packaging Systems’ Role in Sustainability</h2><p>BW Packaging Systems plays a critical role in the supply chain for our customers, which include large and small brand owners that package anything found in a grocery store. These customers are trying to run their businesses more sustainably and to provide more sustainable packagings for consumers. They rely upon us to provide the equipment that will enable them to do that.</p><p>This means we need to provide equipment that is efficient to operate, minimizes waste, and provides them with the ability to package products in more sustainable packaging. Because as materials and packaging companies come up with new solutions that are more sustainable, our customers need to be able to run those materials on our equipment even if our equipment was installed before those materials were invented.</p><p>Our role and responsibility in this whole process is to partner with the materials companies to know what’s coming and to really understand our customers’ needs. This way, we can design equipment that’s not just energy-efficient, but really that’s adaptable, flexible, and can be easily modified to meet new sustainable packaging solutions as the world comes up with them.</p><h2>Guiding Customers Through Their Sustainability Journeys</h2><p>When you’re trying to provide customers with a solution, not just equipment, what’s helpful to them is if you’ve already figured out how to navigate this landscape. Larger companies like Nestlé or Unilever have armies of people who understand the legislation. But smaller companies really value a supplier that understands the complexity of the space that they operate in. Our ability to understand our customers’ journey to finding the right solution is why they trust us.</p><p>For example, we certainly see in Europe a much greater level of attention, focus, and frankly cost benefit with sustainable packaging solutions. The cost of having a non-sustainable packaging solution for a European company tends to be much higher than it is for a U.S. based company due to legislative differences. But since U.S. companies are selling into Europe, they need to understand the local legislation. As an international packaging solution provider, we can help with that.</p><p>This extends to infrastructure too. For example, most yogurt cups are made from polystyrene (PS) – and while PS is recyclable – it’s a material that isn’t generally recycled. When customers want to move from polystyrene, they come to us and ask for alternatives. If you’re operating in Denmark or another country where there’s a very robust industrial composting network, we might say let’s look at PLA because, as a compostable corn-derived bioplastic, PLA might have all those attributes we’re looking for. If you’re operating elsewhere, we might recommend PET because, like PS, it’s a petroleum-derived plastics, except it is highly recycled.</p><p>So, what is the right evolution when you’re coming from a non-sustainable packaging solution? It really depends on your region’s infrastructure, legislation, and several other factors. How do our customers navigate that? That’s part of what we do as a solution provider. We bring that expertise to help them make the right decision about what their packaging solution should be.</p><h2>Systemic Organizational Change</h2><p>As leaders in global business, we need to find new ways to build the organizational competency that will truly drive innovation in this area of sustainability. To me, that’s a multi-faceted challenge. It requires broad expertise and cooperation because sustainability is so complex.</p><p>For BW Packaging Systems, this means having people on our team who bring expertise and knowledge in a wide array of different packaging solutions. It also requires strong industry relations and alignment with materials and packaging suppliers because we don’t want to sell our customers a piece of equipment that is going to be obsolete in two years.</p><p>As my team is spread across the world in all our 28 manufacturing facilities, process becomes essential. We are constantly collecting customer feedback, testing new materials, and sharing our findings across the organization to create the sustainable change our customers and the planet. As the leaders and organizations of the future, this is the systemic change that we need to embed in our organizations.<span style="font-size: small"><strong><span style="font-family: Arial, sans-serif"></span></strong></span></p>