How to balance packaging speed and yield rate?

How to balance packaging speed and yield rate?

——From "efficiency" to "precision", re-understand the value of packaging automation

In packaging automation projects, one of the most common goals mentioned by enterprises is "to be fast" - to increase speed and production capacity as much as possible. Indeed, in large-volume orders and peak production tasks, packaging efficiency is directly related to the shipment progress. But does faster speed really mean higher efficiency?

More and more companies have found a problem after implementing packaging automation: **The production line is indeed running faster, but the complaint rate and rework rate have increased, and the yield rate has decreased. **The problem behind this is actually the balance between "speed" and "stability".

❶ "Fast" ≠ "Excellent": The first principle of packaging is the yield rate
High-speed packaging equipment seems to be incredibly efficient, but if the seal is not firm, the label is off-center, and the loading volume is inaccurate, the cost of rework and repackaging will soon offset the benefits of speed.
More importantly, these "visible speeds" often cover up "invisible losses":

Defective product waste: packaging material loss, raw material waste, manual rework;

Complaint risks: sales terminal returns, damaged brand impression;

System abnormalities: Frequent alarms of sensors, cylinders, and sealing and cutting devices under high-speed operation affect the overall production capacity.

In the project practice of Maike Intelligent Equipment Co., Ltd., many customers paid great attention to the "speed index" at the beginning of equipment selection. But after debugging and verification, they gradually realized that the truly stable, high-precision, and all-weather packaging rhythm that can run without failure is the "optimal solution" that best suits their production line rhythm.

❷ Equipment structure and control system are the core that affects balance
The balance between speed and yield cannot only be achieved by "speed reduction". In fact, the structural design and control strategy of the equipment are the key to determining how high this balance point can be.

Here are a few common examples:

In the design of equipment, Maike Intelligent Equipment Co., Ltd. pays special attention to the adaptive ability of these details to ensure that the equipment can ensure the consistency of action and controllability of errors even at high speed, and reduce defective products from the source.

❸ "Efficiency improvement" does not rely on running fast, but "less stop, less waste, high accuracy"
The ultimate goal of the company's pursuit of efficiency is to achieve controllable and stable output. In other words, it is not the pursuit of "the fastest machine", but the pursuit of "the least overall system stop, the least scrap, and the smallest error".

This is why more and more customers in the food and daily chemical industries pay more attention to these indicators when cooperating with Maike Intelligent Equipment Co., Ltd.:

Single shift output qualified rate ≥ 98%

No more than 2 alarm shutdowns within 8 hours of continuous operation

Changeover time is controlled within 3 minutes

Packaging material utilization rate ≥ 99.5%

Only when every link of the production line is coordinated and efficient and runs stably, can the company truly release production potential from automation, rather than falling into the dilemma of "fast but annoying, slow but loss-making".

✅ Written in the end: Packaging automation is not "the fastest one wins", but "the best balance wins". In every project, Maike Intelligent Equipment Co., Ltd. emphasizes that "technical indicators are not for display, but for the actual production capacity of customers". Speed ​​is appearance, stability is fundamental. In the future, the competition of packaging equipment will not only see who is faster, but also see who can be faster, more accurate and more stable.