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Reducing Tape WASTE and Improving Productivity with Preventative Maintenance

Case Study: Pet Food Manufacturer

Overview

Crawford Packaging recently worked with a premium pet food manufacturer located in the Kitchener/Waterloo Area to improve their automated packaging processes. The Manufacturer experienced carton sealing issues as cases were often being taped improperly, or not at all. The poor tape application required the Manufacturer to stop production and fix the production problem.

One of Crawford’s Packaging Specialists visited the Manufacturer’s facility to perform a Tape It Right audit. The Packaging Specialist discovered the Manufacturer’s equipment had worn parts that needed to be replaced. The Packaging Specialist recommended Crawford’s tape head program to the Manufacturer. This program provides regular maintenance and a spare parts kit for the tape heads to keep the Manufacturer’s equipment operating smoothly.

 photo of a large white dog being fed a treat by a human hand

Challenge

These production stoppages cost an average of 100 production hours a month, resulting in an estimated $1,000,000 in losses per month.

A premium pet food manufacturer was experiencing high rates of misapplied tape in their automated packaging equipment. These defective seals required the Manufacturer to stop production, assess the cause of the error and reseal the affected cartons. These production stoppages cost an average of 100 production hours a month, resulting in an estimated $1,000,000 in losses per month.

Process

Crawford’s Packaging Specialist visited the Manufacturer’s facility to perform a packaging consultation as a part of the Tape It Right program. The consultation identifies the Manufacturer’s tape issue by assessing their machine carton sealing tape, packaging equipment and processes. The Tape It Right analysis revealed the issue was a result of worn, inefficient tape heads.

As a solution, the Packaging Specialist recommended Crawford’s preventative maintenance and tape head program. This program would measure tape head wear by matching the Manufacturer’s tape purchases with the recommended tape head maintenance times. The Manufacturer was provided with a high-speed tape head to test on one of their random case sealers.


Solution

Crawford’s Tape It Right Program

Tape It Right works with clients to audit and review their existing case sealing practices and equipment. This will improve sealing efficiency and productivity through the identification and standardization of improved case sealing practices. Through this standardization, Tape It Right has helped businesses save up to 30% on their annual carton sealing costs.

30-Micron Production-Grade Hot Melt Packaging Tape

Production-grade hot melt packaging tape creates instant closures on medium-weight cartons in everyday manufacturing and shipping environments. For manual or automated industrial carton sealing applications, this 30-micron tape provides excellent holding power and superior performance. The Hot Melt tape uses a special release coating for a consistent, low force unwind off the roll for easy feeding and reduced breakages.

High-Speed Tape Head

Crawford’s High-Speed tape heads can be easily retrofitted to fit any case forming or case sealing equipment. Pairing the High-Speed Tape Head with a 30-Micron tape allowed the Manufacturer to reach unparalleled levels of performance. The high-performance tape heads advanced design ensures consistent pressure during tape application for improved effectiveness. The consistent pressure results in a stronger bonding process of tape and carton material. The accuracy of Crawford’s high-speed tape heads will improve packaging throughput and reduce labour costs by reducing miss-tapes. Once sealed, folded-edge technology makes opening boxes an easy, toolless experience.

Tape Head Program

The tape head program offered as part of Crawford’s Tape It Right and Preventative Maintenance programs monitors tape consumption to improve maintenance. Crawford’s factory certified technicians will educate maintenance teams, highlighting wearable parts and their importance. This helps in-house maintenance teams to understand the parts roles and increase their effectiveness when troubleshooting issues. The program also provides spare parts kits at ordering increments that prompt replacement of the tape heads wearable parts.

 photo of an automatic case sealing system with a flexible conveyor moving white cardboard boxes

Results

Following the trial period, the Manufacturer chose to join Crawford’s tape head program to ensure an efficient and effective tape solution. This knowledge-based, and impactful solution helped the Manufacturer improve their carton sealing. The solution has eliminated tape waste, reduced consumption, reduced labour costs, and eliminated costly production downtime.

 solid blue icon of a garbage can

Reduced Packaging Tape Waste and Consumption

The new high-speed tape heads helped the Manufacturer to greatly reduce their packaging tape waste and consumption. With new tape heads, the Manufacturer eliminated their tape application problems. Cases that pass through the automated carton sealing and carton forming equipment are sealed effectively each time. This helped the Manufacturer reduce tape consumption and waste caused by the correcting misapplied tape.

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Increased Productivity and Throughput

The tape head efficiency helped the Manufacturer to greatly improve their automated packaging productivity. The elimination of misapplied tape eliminated packaging shutdowns and increased throughput levels. The improved preventative maintenance offered by the tape heads program has helped the Manufacturer maintain their efficiency and keep up with peak production levels.

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Reduced Labour Costs

With tape being applied properly the first time, the Manufacturer better utilizes their labour force. The Manufacturer's operators now run their automated equipment for longer periods and employees no longer have to spend their time correcting defective tape seals.


Crawford Packaging is a full-service packaging company located in London, Brampton and Waterloo, Ontario. From packaging to packaging equipment, installation and upgrades, and in-person equipment training and repair, we're focused on your business success every step of the way.