Packed With Expertise Blog

May 26, 2022

<h2>Shrink Sleeve vs Pressure-Sensitive Label Application</h2><p>There is an ongoing and rigorous debate about which label technology is best. Both pressure-sensitive and shrink sleeve label applications have their place. The choice between the two really depends on your needs and how each piece of machinery aligns with your company’s brand and brand packaging strategy. This article highlights some of the main differences between the two label applications. You can also download the&nbsp;<a href="https://5605328.fs1.hubspotusercontent-na1.net/hubfs/5605328/Accraply/PS%20vs%20SS%20Infographic%202.pdf" data-sf-ec-immutable="" data-sf-marked="" target="_blank">infographic</a>&nbsp;for quick reference.&nbsp;</p><h3>Pack Formats</h3><p>Packaging formats play a big role in determining which label technology will work best for your needs. pressure-sensitive Labeling works only with flat or panel-shaped packaging, while shrink sleeves work well for more complex shapes, allowing for full body decoration on curved items.</p><h3>Integration Ease</h3><p>Floor space and ease of integration are also key considerations in labeling application decisions. Pressure-sensitive labeling machines utilize a smaller footprint and are easy to integrate into existing packaging lines. &nbsp;Shrink sleeve labeling machines require a larger operating space, to accommodate the shrink tunnel requirements.</p><h3>Shelf Appeal</h3><p>Both shrink sleeve and pressure sensitive labels provide strong shelf appeal for your products. Shrink sleeve application enables full-body decoration, giving brand owners the best opportunity to utilize color and shape to make their products stand out from any angle on the shelf. Pressure-sensitive labels utilize embossing, high-resolution printing, and 3D graphics to help products stand out in unique ways.</p><h3>Capital Expenses</h3><p>While there are different ranges of expense for each application based on quality, speed, and durability, on average pressure sensitive labeling machines cost less than their shrink sleeve counterparts. &nbsp;This is due to the two-stage process required to apply and shrink a shrink sleeve label. In general, pressure-sensitive labels cost less per label than shrink sleeves.&nbsp; It is important to evaluate the Total Cost of Ownership (TCO) to help determine which labeling option works best for your organization.</p><h3>Tamper Evident/Security &nbsp;</h3><p>If your packaging requires tamper-evident or security labeling, both pressure sensitive and shrink sleeve label applications can create a tamper-evident seal. The shrink sleeve label application is an easier method to integrate tamper-evident labeling. You can have a small machine dedicated to tamper-evident labeling added to a production line. While for pressure-sensitive applications, it needs to be integrated within the pressure-sensitive labeler and would need to be planned from the initial purchase of the labeler.</p><h3>Operational Requirements</h3><p>Another consideration when choosing between pressure-sensitive and shrink sleeve label applications is the type of production line you are running. Shrink Sleeve applicators require accumulation handling for intermittent (start/stop) production lines. This requirement is driven specifically by the need for a steady state of product flow into and out of the shrink tunnel to maintain a high-quality product presentation.</p><h3>Temperature Sensitivity</h3><p>Depending on your manufacturing environment, pressure-sensitive labeling may be the most effective labeling solution for you. Pressure-sensitive labeling applicators can perform in a variety of different temperature states. An environment where condensation occurs may require some additional equipment to dry the container prior to shrink sleeve product decoration.</p><h3>Sustainability</h3><p>Your company’s sustainability strategy may also impact your choice of label and labeler. Pressure-sensitive labeling machines can accommodate all preformed materials (PP, PET, glass, cardboard, etc.), offering numerous labeling options that impact sustainability in various ways. Shrink sleeve labels, on the other hand, can be easily removed by the consumer and discarded to allow for container recycling without concern for label recyclability.</p><h3>In Conclusion</h3><p>In the end, there are numerous considerations to keep in mind when choosing between shrink sleeves and pressure-sensitive labels. The choice often comes down to your company’s specific needs. Accraply has put together a quick reference infographic for you.&nbsp;<span style="background-color: initial; font-family: inherit; font-size: inherit; text-align: inherit; text-transform: inherit; white-space: inherit; word-spacing: normal; caret-color: auto">If you need assistance in choosing what application works best for you,&nbsp;</span> <a href="https://www.accraply.com/contact-us" data-sf-ec-immutable="" style="font-family: inherit; font-size: inherit; text-align: inherit; text-transform: inherit; white-space: inherit; word-spacing: normal" data-sf-marked="" target="_blank">Contact Accraply</a>.</p><p>&nbsp;</p>

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 14, 2021

<p>Spurred by the sustainability movement and the rise of SMART technology, downgauging has become a popular trend in shrink sleeve films. This has created a significant impact on shrink sleeve equipment and technology, as equipment providers have been challenged to modify their shrink-sleeve cutting machines to cut thinner films and upgrade their software to increase end user accessibility. Companies like Accraply are making advancements to stay ahead of customer demands while maintaining OEE.</p><p>Richard Howlett, Accraply’s Global Product Line Leader, was recently&nbsp;<a href="https://www.packagingdigest.com/labeling/shrink-label-applicators-whats-new-and-whats-next" data-sf-ec-immutable="">interviewed by Packaging Digest</a>, to share his insights on how shrink sleeve applicators are evolving to meet these challenges. The following is an excerpt from his interview.</p><p><strong>What recent advancements have you seen in shrink-label applicators?</strong></p><p>The shrink-sleeve film market is very dynamic with new and more advanced shrink films being developed continuously. These advancements are certainly having an impact on shrink-label application machines. The most significant trend that we see is the downgauging of shrink films. This has an impact on the design of shrink-sleeve application machine cutting system. The cutting systems are now required to cut thinner, softer films at higher speeds.</p><p><strong>How do these advanced systems compare to the existing standard equipment?</strong></p><p>With the trend to cut thinner, softer films at higher speeds, control of the shrink-sleeve during the cutting cycle is critical. These systems generally use the most advanced controls to allow maximum control of the sleeve during the cutting process. With the need for control being paramount, we see the need to monitor OEE in the form of advanced data-gathering and diagnostics. To achieve this, SMART human-machine interface (HMI) technology is used in many shrink-sleeve application machines, giving the end user full transparency and understanding of how their shrink-sleeve system is performing.</p><p><strong>What are the benefits of these advancements for packaging machinery buyers/users?</strong></p><p>The benefit for the buyers/users is that if the correct sleeve-application machinery is selected, then the machinery will be advanced enough to cope with the trend of cutting thinner, softer films at higher speeds, thus opening up the market for the user to use a wider range of shrink films and offering more options to brand owners, with thinner films reducing weight and volume for logistics, and reducing CO2 emissions.</p><p><strong>What areas in shrink-label applicators still need work and why?</strong></p><p>The areas of a shrink-label system that are being worked on are that part of the system that can be deemed the most challenging, which are the shrink tunnels. With the continued advancement in shrink film, shrink tunnels are equally important parts of the process and are being advanced in technology in the pursuit of providing the perfectly finished shrink-sleeve labels. Selecting the correct tunnel is critical to produce the best possible final appearance of the product.</p><p><strong>What’s next and when might we see further improvements in shrink-label applicator machinery?</strong></p><p>As the industry continues to keep a watchful eye on sustainability and the carbon footprint, the industry may make improvements in ways to shrink the sleeves using less energy and with more use of renewable energy.</p><p>For more information, contact Accraply to learn more about their shrink sleeve solutions.&nbsp;<strong></strong></p>

April 7, 2021

<h2>Improving OEE</h2><p>Consumer products manufacturers are always exploring ways to improve operational efficiency. Improving overall equipment effectiveness (OEE) requires procurement and engineering leaders to solve a handful of key challenges, which include improving operator training, quickly resolving unplanned downtime, and streamlining access to technical support services.</p><p>With consideration of these challenges, today’s manufacturers of automatic labeling machines have invested in developing human-machine interfaces (HMIs) that can significantly improve OEE. These HMIs can provide greater access to training resources, intuitive technical documentation, and technical support for on-the-spot troubleshooting.</p><p>In this post, I’ll explain how smart HMIs can improve operational efficiency for consumer products companies and provide a list of HMI features to consider when purchasing a new labeling machine.</p><h2>How Smart HMIs are Changing the Market</h2><p>HMI technology has improved rapidly over the past three years. Instead of the flashing warning light of years gone by, today’s HMIs can display an image of the machine, place an indicator where the exact fault is, and provide instructions for how to resolve the issue. They offer significant advances in user experience, including improved graphics, enhanced connectivity, larger screen sizes, and multi-touch functionality. They also provide greater access, not only to a machine in its current state but also to information that can be used to improve the machine’s performance throughout its lifecycle.</p><p>Advanced panel-based HMIs, such as BW Packaging's award-winning Opview™ HMI, are forecasted to achieve a high market growth rate due to the demand for mobile HMIs. The ability to connect with a machine remotely and to access all the information required to provide greater insight into labeling operations, and thereby increase the overall productivity of the plant, is more desirable than ever. COVID-19 has also reinforced the importance of remote connectivity and simplification of operations.</p><h2>Labeling HMI Checklist</h2><p>When choosing an automatic labeling machine, there are several HMI-related criteria that should be considered that can improve OEE. Below is a list of questions that can be used to evaluate labeling machine HMIs and compare options from various suppliers.</p><h3>1. Operator Training Resources</h3><p>How will this HMI improve operator training? Some HMIs include video tutorials and on-demand training guides to make setup and operations simple. They can also come with step-by-step onboarding for key functions, maintenance, and fault recovery processes, including how to maximize machine speed. They may even be available in multiple languages for today's multi-national workforce.</p><h3>2. Streamlined Troubleshooting</h3><p>Does the HMI provide links and instructional steps to help you clear faults? HMIs can walk operators through the steps to resolve the fault and reset the machine. Having this functionality as a part of the HMI means operators don’t have to consult manuals. They can address the issue on the spot, keeping downtime to a minimum.</p><h3>3. Preventive Maintenance Reminders</h3><p>Does it allow you to schedule preventive maintenance reminders? Reminders can appear as daily, weekly, and monthly tasks for your operator and maintenance team. By taking a proactive approach to machine maintenance, operators are better able to avoid unplanned downtime.</p><h3>4. User Levels</h3><p>Can you control access and accountability? To drive consistency of performance, some HMIs allow you to set different user levels, limiting access to parameters and/or range of adjustments, as you deem necessary.</p><h3>5. Offsite Connectivity</h3><p>Can the HMI connect remotely? For example, some HMIs allow operators to access machine configuration off-site and even allow them to set up audit trail information from a computer, tablet, or smartphone.</p><h3>6. Remote Support</h3><p>Does the labeling machine manufacturer provide remote support via the HMI? Having your OEM remote in the machine via the HMI can help operators resolve issues more quickly and cost-effectively.</p><h3>7. Rapid Changeovers</h3><p>Is the HMI designed to accommodate rapid changeovers? Some HMIs store recipes and provide video changeover guides to assist operators in reducing downtime between changeovers and to start up faster.</p><h3>8. Productivity Reporting</h3><p>Can the HMI show complex data, such as machine OEE, in real-time? This feature can show operators where a fault lies and offer remedies to fix that fault, which can help improve the long-term effectiveness of the machine. This feature can be accessed on-screen and in real-time via video assistance.</p><h2>BW Packaging's OpView™ HMI</h2><p>BW Packaging has designed an HMI that satisfies all of the criteria listed above. OpView™ HMI simplifies operation and training and provides greater access to an advanced analytics dashboard. In addition, because the OpView™ is now standard on BW Packaging equipment, operators transition easily from one machine to the next as they move through the guided onboarding, intuitive navigation, and clear functional parameters.</p><p>The OpView™ HMI was recognized for design excellence with its smart user interface (UI), earning two IF Design awards in the prestigious global design competition that evaluates design excellence across many industries. The award called out the Opview™ HMI for “an outstanding focus on the interlinked factors of human, task, process, and machine.” It provides one interface for all machine types, fast access to all information, and user-friendly navigation. Adding to the package the clear alarm system and easy-to-understand troubleshooting workflows, the Opview™ HMI makes a whole new level of operation easily accessible for customers.</p>