How to Avoid Downtime Caused by Poor Packaging Consumables

Understanding the Hidden Costs of Poor Packaging Consumables

Downtime caused by poor consumables is rarely an isolated event—it often results in multiple issues:

• Machine stoppages due to jams, breakages, or incompatibility.
• Increased rework from improperly wrapped or sealed products.
• Product damage during transport or storage.
• Higher waste levels, impacting both cost and sustainability targets.

These issues can compound. For instance, a weak stretch film may tear mid-cycle, causing the machine to stop, operators to remove incomplete wraps, and the load to be restarted—resulting in minutes or even hours of lost productivity.

Stretch Film (Manual and Machine) – The First Line of Load Protection

Stretch film is one of the most critical consumables in securing palletized loads. However, not all films are created equal, and using the wrong type can lead to frequent downtime.

Common Problems:

• Film breakage during wrapping: Often caused by insufficient puncture resistance for irregular loads.
• Overstretching or under-stretching: Results in unstable loads that may require re-wrapping.
• Incompatibility with wrapping machines: Film not designed for high-speed machines can cause frequent feed interruptions.

Best Practices:

• Match film gauge and elongation properties to load weight and shape.
• Use pre-stretched or high-performance films for machine wrapping to reduce tension inconsistencies.
• Regularly calibrate machine settings to prevent unnecessary stress on the film.

Shrink Film – The Key to Product Presentation and Protection

Shrink film is used widely in food, beverage, and consumer goods packaging. Downtime can occur if the film reacts poorly in heat tunnels or is not suited to the product’s dimensions.

Common Problems:

• Uneven shrinkage: Leads to poor aesthetics and compromised protection.
• Film burn-through or wrinkling: Often due to incorrect heat tunnel settings or poor film quality.
• Sealing failures: Result from low-quality seal layers that break under minimal stress.

Best Practices:

• Choose film with the right shrink ratio and sealing properties for your application.
• Verify film compatibility with the tunnel’s temperature and conveyor speed.
• Store film in a controlled environment to prevent moisture or temperature-related degradation.

Pallets – The Foundation of Load Stability

Whether plastic or wooden, pallets are the base on which all unit loads depend. If they fail, the entire load—and the production line—can be compromised.

Common Problems:

• Damaged boards or deck slats: Can puncture stretch film or cause product instability.
• Incorrect pallet size: Leads to overhanging loads that are prone to damage.
• Poor structural integrity: Results in collapsing stacks during storage or transit.

Best Practices:

• Use plastic pallets for environments that require hygiene and consistent dimensions, and wooden pallets for heavier static loads if cost efficiency is a priority.
• Inspect pallets regularly and replace damaged units before they enter production.
• Standardize pallet specifications across the operation to ensure uniform handling.

Adhesives and Hot Melt – The Backbone of Secure Packaging

Industrial adhesives and hot melt are critical for sealing cartons, bonding materials, and securing protective elements. Poor performance here can cause both minor and major downtime events.

Common Problems:

• Weak bonding: Leads to package failures during transport.
• Clogged applicators: Caused by adhesives with inconsistent viscosity or impurities.
• Excessive residue: Requires time-consuming cleanup and maintenance.

Best Practices:

• Select adhesives rated for the specific substrates and environmental conditions.
• Maintain equipment temperature settings to avoid overheating or underheating.
• Partner with suppliers who guarantee batch-to-batch consistency and FDA compliance when applicable.

Sealants and Lubricants – Small Products with a Big Impact

Sealants and lubricants may seem secondary to the main packaging process, but they play a vital role in equipment performance and product protection.

Common Problems:

• Sealant failure: Causes leaks in liquid packaging or insufficient protection against contaminants.
• Inadequate lubrication: Leads to excessive wear and tear, resulting in unexpected breakdowns.
• Contamination issues: Poor-quality products can introduce foreign particles into production lines.

Best Practices:

• Use lubricants formulated for industrial equipment, ensuring proper viscosity and compatibility.
• Follow manufacturer’s recommendations for application frequency and quantity.
• Train operators to identify early signs of lubrication or sealant failure.

Supplier Reliability – The Overlooked Factor

Even the highest-quality consumables are useless if they’re not delivered on time. Late or inconsistent supply creates the risk of last-minute substitutions with inferior products, often leading to downtime.

Best Practices:

• Work with suppliers that maintain stock availability and offer short lead times.
• Establish long-term supply agreements for critical consumables.
• Audit suppliers for quality consistency, technical support, and emergency fulfillment capabilities.

Proactive Strategies to Reduce Consumable-Related Downtime

To keep your operation running smoothly, adopt a preventive and data-driven approach:

• Conduct regular packaging line audits to spot recurring failures or inefficiencies.
• Track consumable performance metrics, such as film break rates, adhesive failures, or pallet damage incidents.
• Train staff on proper handling, storage, and application of each consumable type.
• Collaborate with technical teams from your supplier to test new products under real production conditions before full implementation.

The Bottom Line

Poor packaging consumables can undermine even the most advanced production setups. The direct costs of replacement and rework, combined with the indirect costs of lost productivity and customer dissatisfaction, make it essential to treat consumables as strategic assets—not afterthoughts.

By carefully selecting, testing, and maintaining stretch film, shrink film, pallets, adhesives, hot melt, sealants, lubricants, and other consumables, companies can prevent costly interruptions, improve efficiency, and safeguard product quality.