Predictive maintenance reduces packaging waste by addressing inefficiencies along the line. Unlike other solutions, it does not require extensive retrofitting or substantial investments, making it ideal for small, medium and large companies. You can consider it your secret weapon since it will generate significant gains without drawing attention.

The Packaging Industry Has a Waste Problem

Packaging waste is a considerable environmental and economic challenge for manufacturing companies. It consumes valuable natural resources and generates greenhouse gas emissions, raising logistics expenses and increasing distribution complexity. Reducing waste generation is vital. However, companies cannot simply remove packing and wrapping from production.

Handling waste on-site or paying contractors to handle it takes time, money and energy that could be better spent on driving business value. Workers must collect, clean, transport and dispose of scraps and defective units.

Doing nothing is not an option. In addition to risking negative public perception, leaders would inadvertently make themselves less competitive. Those who eliminate wasteful practices will align their processes with rising sustainability awareness and decrease overhead expenses. As a result, their brand reputation improves, and they can pivot more easily.

Why Should You Care About Reducing Waste?

Most consumers pay attention to how sustainable brands are. In a 2022 study, 63% of respondents agreed they are more likely to buy products with clearly labeled recycling instructions. However, 59% said finding guidelines on proper disposal is difficult. As consumer demand becomes increasingly robust, taking action will become increasingly urgent.

Another trend prompting action is increased regulatory scrutiny — plastic bans and emission regulations are rapidly reshaping manufacturing to promote sustainability. Packaging may not be the most unsustainable process, but it is under scrutiny because it has a substantial environmental impact. According to the U.S. Environmental Protection Agency, containers and packaging comprised 28.1% of municipal solid waste generation in 2018 — the latest year for which statistics are available — totaling 82.2 million tons.

Focusing on Equipment Health Over Product Design

Since packing is the final production stage, aligning speed and quality while addressing evolving operational challenges is essential. However, packaging lines often face a high risk of unplanned downtime due to the need for repetitive manual labor.

While the industry’s workforce has grown over the last decade, the pandemic-related e-commerce boom has created labor shortages. Many businesses have invested in automation technology to meet demand. Even though these machines only exist to streamline production and improve uptime, substandard maintenance schedules are common.

Many facilities rely on run-to-fail maintenance programs, only performing repairs after equipment breaks. As a result, they accumulate significant order backlogs, have trouble sourcing spare parts and must supplement in-house technicians with outsiders. This leads to increased maintenance costs.

Predictive maintenance reduces packaging waste by prioritizing equipment health over product design. It helps improve uptime and speed, raising the production rate without increasing the volume of packing defects.

What Makes Predictive Maintenance a Secret Weapon?

Predictive maintenance provides a subtle competitive advantage. There is no need to extensively overhaul your processes or undergo major retrofitting. Installing sensors and internet-enabled devices for remote monitoring is relatively simple and cost-effective. You can easily hide your technique to gain a competitive advantage strategically.

Insights into machine health tell you what shape your packaging facility’s equipment is in. This data-driven method makes connections clear, enabling you to accurately identify downstream effects with ease.

Internet of Things devices can capture motion, voltage, vibration, flow or pressure data, among other things. For example, a sensor can track oil level, pressure and temperature, even going as far as detecting leaks. Plugging these metrics into a connected dashboard enables you to determine equipment health, enabling proactive repairs.

A platform makes the data actionable by conducting analyses and sending alerts. Depending on the solution you select, you could connect your sensor network with artificial intelligence to accurately review data and identify anomalies in real time.

Predictive maintenance reduces packaging waste by improving machine accuracy and reducing the line’s error rate. Also, it can improve equipment reliability, enhance quality compliance, support operator safety and decrease replacement costs. It pays dividends, reducing overall operating expenses.

How Predictive Maintenance Eliminates Waste

Predictive maintenance reduces packaging waste by decreasing energy consumption, diminishing material usage, extending equipment lifespan, reducing oil waste and supporting a closed-loop system.

IoT sensors can detect slight changes in energy consumption, enabling your technicians to fix underperforming machines in real time. Alternatively, you can connect the devices to a smart hub to automate settings adjustments. Either way, your utility bills will drop.

Preventing Equipment Faults

A single fault can cause a cascade of issues down the packaging line. Whether you have a capping machine with inconsistent torque or a vacuum packaging tool that applies seals poorly, identifying the problem early on can keep it from snowballing. These improvements extend to the supply chain, helping prevent damage during distribution.

Minimizing Replacements

This maintenance technique extends your equipment’s lifespan. The better shape your machines are in, the fewer replacement parts you have to order. You produce less electronic waste — which is set to increase by 33% from 2022 to 2030, reaching 82 million metric tons — as a result, improving your environmental impact while saving money.

Eliminating Oil Waste

Embedded sensors can conduct oil analyses by monitoring viscosity, acid number and water content. You will receive an alert if any metrics approach a predetermined threshold. Performing proactive repairs to prevent leaks and contamination will reduce your oil waste.

Supporting a Closed-Loop System

Mitigating oil, energy, mechanical and material losses through predictive maintenance generates substantial savings. You can put these funds toward a closed-loop system, creating a positive feedback loop that minimizes waste. For example, you can invest in energy-efficient automation solutions to maximize your gains.

Predictive Maintenance Is Your Secret Weapon

Although predictive maintenance reduces packaging waste indirectly, it is still an effective solution. Internet-enabled sensors are small and affordable, so installation is straightforward — whether you want to improve the packaging line or delivery vehicles.

Unlike automation technology or recycling machinery, these devices are subtle. Your competitor could walk around the production floor and not realize you are monitoring your equipment’s health. A strategic implementation plan can turn this technology and its associated maintenance technique into your secret weapon.