From filling to cartoning and shrink wrapping, packaging machinery can significantly improve production efficiency, product quality, and profitability.

Such benefits are vital as consumer demands evolve and competition grows.

However, packaging machinery typically has a lifespan of around 10 to 15 years, which represents a realistic and effective period for delivering performance, efficiency, and return on investment.

As machinery approaches the later stages of its lifecycle, it is more likely to require increased maintenance and may struggle to meet evolving product requirements and sustainability expectations. Changes in product types, sizes, and materials can also reduce the suitability of existing equipment, making replacement or upgrade a practical consideration rather than a failure of the asset.

Read on as we highlight the key factors to consider when replacing existing systems or extending manufacturing capacity.

When Is It Time to Replace Your Packaging Machinery?

Identifying when equipment has reached the end of its operational life can be challenging, particularly when there is a temptation to control costs through short-term repairs. While this approach may appear economical in the moment, delaying replacement of ageing or underperforming machinery can have a significant impact on long-term efficiency.

Continued use of failing equipment increases the risk of product damage, quality defects, and inconsistencies, which can ultimately lead to higher levels of waste, customer complaints, and reputational impact. Where the cost of ongoing repairs becomes excessive, or where there is little prospect of restoring the machinery to optimal performance, replacement becomes a necessary and strategic decision rather than a discretionary one.

It is also important to consider how changes in product formats, sizes, materials, and sustainability requirements may affect existing equipment. Looking ahead and planning for future needs can help avoid sudden obsolescence and unplanned disruption to production.

At this stage, developing a clear and well-considered User Requirement Specification (URS) is critical. A robust URS enables machine suppliers to accurately quote and design a high-quality system that meets both current and future operational requirements. Investing time upfront in defining these needs can significantly improve outcomes, reduce risk, and support better decision-making throughout the procurement process.

Key Considerations When Choosing Packaging Machinery

Various factors will have a bearing on the best choice of packaging machinery.

Time will ideally be spent preparing the business case, with everything from the manufacturing objectives to the risks and benefits of installation being covered.

Product and packaging type

Product and packaging characteristics are a critical consideration, with machinery ideally offering the flexibility to handle items of varying weight, size, and fragility, as well as accommodating new product and packaging designs.

This may include the need for gentle handling of delicate food products or the precise and accurate filling of liquids. Ensuring machinery capabilities are well matched to specific materials is essential for maintaining product integrity and consistent packaging quality.

It is also important to recognise that the move towards more sustainable packaging materials can be incompatible with older or legacy machinery, often requiring updated systems or greater adaptability.

The greater the flexibility and versatility of the equipment, the more likely it is to support evolving requirements and continue to meet future packaging needs.

Compatibility with Existing Lines

Packaging machinery must be compatible with your product line and manufacturing processes.

Checks should be made to ensure that it will work effectively with existing conveyors, fillers, and labellers, minimising the need for potentially costly retrofitting.

There’s every chance that the integration of a new machine will make for greater functionality, increasing the capacity for products of different sizes and formats.

Scalability and Future Growth

Modular and upgradeable systems are particularly recommended for manufacturers in fast-changing markets.

Scaleable machinery will allow for gradual increases in production, product range diversification, and the development of new formats.

Such flexibility will be especially valuable, given the introduction of new sustainability targets and packaging regulations.

Space and Layout Requirements

Packaging machinery could cause more harm than good if it isn’t of a suitable size and format for your production environment.

So, take the time for a thorough assessment of the available floor space and compatibility with your current workflow.

Seamless integration should be assured, with access for maintenance and operator safety zones.

Operational Efficiency and Sustainability

The efficiency of your chosen packaging machinery is also a critical factor, particularly given the increasing focus on waste minimisation and sustainability.

Modern machinery may support the use of alternative, eco-friendly packaging materials, such as replacing foam chips with paper-based void fill. Newer systems are also more likely to enable higher production speeds, supported by AI-powered monitoring and remote diagnostics, which help optimise planned maintenance schedules and significantly reduce the risk of unplanned breakdowns.

Budget and Ongoing Costs

Cost will undoubtedly be a key consideration when investing in replacement packaging machinery. However, it is important to look beyond the initial purchase price and consider the total cost of ownership over the equipment’s lifespan.

This financial assessment is typically carried out in consultation with the machinery supplier, who should be able to outline expected ongoing costs such as maintenance, replacement components, energy consumption, and potential residual value at end of life. There may also be flexible funding options available, including staged payments or leasing arrangements.

Warranties should be reviewed carefully, as these can cover maintenance and repair costs for a defined period and contribute to greater cost certainty in the early years of operation.

Finally, return on investment (ROI) should be assessed over a realistic timeframe. While UK businesses often focus on a two-year payback period, packaging machinery is typically a longer-term asset. Evaluating ROI over a longer horizon can provide a more accurate reflection of the operational, efficiency, and sustainability benefits delivered over the full lifecycle of the equipment.

Supplier Reliability and Support

There should be the assurance of continued support following the investment in packaging machinery.

Ideally, you’ll choose a local and reputable supplier, with the assurance of rapid repairs and emergency servicing as required.

The details of such support should be specified in a service-level-agreement, with a regular maintenance schedule to keep the machinery working effectively.

You can verify the credentials of such suppliers through Automate UK’s product finder.

The annual PPMA Show also provides the opportunity to explore new packaging technologies, with live demonstrations focused on known production needs.

New vs Second-Hand Machinery

You may be tempted to pay the premium for new packaging machinery for reasons of quality and reliability.

Such machinery may promise a significant improvement in efficiency, with a lengthy warranty for your peace of mind.

However, it’s worth considering the cost-effectiveness of second-hand machinery, some of which may have had very limited use.

Second-hand machinery may also be quickly and easily deployed, particularly for SMEs or trials.

Just take care, ensuring that such machinery matches your specifications and is defect-free.

Narrow down the selection of potential suppliers for full consideration of the machinery and service offerings.

Making the Right Decision

Ultimately, you should look for packaging machinery that will enhance performance at minimal cost and risk.

The process should begin with the mapping of operational needs against manufacturing objectives such as the improvement of speed, yield, and uptime.

Scaleability, sustainability, and compatibility with existing systems should all be taken into account.

The checking of supplier due diligence will also be vital, with the Automate UK Product Finder allowing for the comparison of certified providers.

Going beyond the capital purchase, this should be an investment for enhanced production capability, workforce efficiency, and brand reputation.