Packaging machines are becoming faster, more flexible, and more sensitive at the same time. While robotics, AI, and new materials are in focus, the performance of the machine is often determined at a much less visible point: where the human intervenes. When properly selected, standard and operator components have the potential to improve productivity, process reliability, and the quality of the final product.
In modern packaging systems, complexity is compressed into a small space. High speeds, changing formats, strict hygiene requirements. The major issues are well known. What is less well understood is that exactly here, standard and operating parts play a central role. They are not an afterthought. They are the operational interface between operator, machine and product and must ensure that the requirements are met. Among other things, it involves a design that is easy to clean, material compliance, vibration resistance and optimal usability under time pressure.
„The packaging industry is a very large and versatile field,“ emphasizes Samuel Rasch, Team Leader Product Management at Kipp. „Some of our customers develop filling and packaging solutions for the beverage, food, and pharmaceutical industries. In these areas, aspects such as hygiene and detectability are an important topic. For users from the non-food sector, as well as manufacturers of end-of-line packaging machines, topics such as formatting and sensors are more important.“
Flexible guidance and stable support
The foundation of a packaging system is first and foremost reliable conveyor technology. Variable formats, sensitive surfaces and varying process conditions place high demands on the guidance and stability of these systems. Conveyor tracks must be flexible enough to adapt to different transport tasks, while downtime caused by insufficient guidance or unstable designs must be avoided.
Adjustable side guides ensure precise alignment of the conveyed product and can be quickly adjusted to new product dimensions. In addition, various holder and clamping variants support easy integration into existing systems. Special side guides also reduce friction between the guide and product, enabling gentle transport of even sensitive goods.
„In addition to the guidance system, the stability of the conveying structure plays a crucial role in ensuring process reliability. Individually adjustable support elements prevent deformation and ensure a permanently precise alignment of the conveyor belt. Suitable pipe connectors enable stable transverse connections and a flexible adaptation of the design to different plant concepts.“
Samuel Rasch, Team Leader Product Management at Kipp
Speed forces simplification
Packaging lines today run at several hundred cycles per minute. At the same time, the number of parts per batch is decreasing. „A common format change is the rule,“ explains Samuel Rasch. „With this, the focus shifts from the process to the setup phase. If poorly planned, this often takes minutes that add up over the course of the day. Our clamping levers, clamping systems, and locking pins can improve efficiency in this area. They replace the classic screw connection and enable tool-free operation.“
A typical example is the format adjustment on a labeling machine. Handwheels bring the labeling head to the desired height, position indicators provide reproducible values, and clamping levers fix the side guides. The goal is clear: conversion without trial and error. Position indicators play a central role here. Mechanically or digitally, they display precise adjustment values. A once-defined value can be reproduced at any time. This reduces waste after a change.
Sensors are changing the role of standard parts
A clear trend is the integration of sensors. Standard parts are becoming information sources. Kipp is leading the way with its feature-grip series. „We are moving away from pure mechanics towards smart components,“ explains Samuel Rasch. „A locking bolt indicates whether it is properly closed. A resilient pressure piece or a stop indicates its end position. The machine only starts up when everything is in order.“ This is not a convenience feature, but risk management. Misoperation is systematically excluded. Accidental damage after hectic format changes can be significantly reduced. At the same time, process transparency increases.
The question of complexity and cost remains critical. Sensorics increases the integration effort and the dependence on control systems. However, in highly automated lines, the benefits outweigh the costs, as downtime is more expensive than the additional components.
Hygiene requirements in the food and pharmaceutical industries
In food and pharmaceutical applications, standard and service parts must meet hygiene requirements and also withstand aggressive cleaning processes. Stainless steel is the standard here, usually in A2 or A4 quality. Plastics must be FDA-compliant, often even detectable. Surfaces must not have microstructures that can form biofilms. Open threads, sharp edges, or blind holes pose a risk. Liquids should flow through the components, not stagnate.
To meet these requirements, Kipp offers standard and customized components in hygienic design, that is, with consistently closed geometries, rounded radii, and sealing systems such as Hygienic U-Seal gaskets that completely seal the screw connections. At the same time, materials that withstand the stress of CIP and SIP processes are required. Fluoroprene seals or sealing elements made from ethylene-propylene-diene monomers (EPDM), a synthetic rubber with high resistance to weathering, ozone, and UV radiation, are therefore the prerequisite for durability and process stability.
Material choice crucial
The choice of materials is strategic in packaging machines. Stainless steel is the material of choice in corrosive environments, while polyoxymethylene (POM) and polyamide (PA) are used where low weight, electrical insulation, or specific sliding properties are required. Detectable plastics, in turn, are proven in safety-critical areas. High-performance plastics increasingly replace metal where it is technically feasible. This reduces moving masses and therefore also energy consumption. At the same time, mechanical stability is maintained. Antibacterial materials are also gaining in importance. In its Medi-grip product line, Kipp uses plastic materials enriched with silver ions. These actively combat bacteria (such as MRSA or E. coli) and prevent the formation of biofilms on the surfaces of the grippers.
In the packaging industry, overall equipment efficiency counts. Norm and operational parts influence this more than often assumed. Corrosion, wear, or loosening due to vibration lead to downtime. Kipp addresses this with material robustness and structural details such as polyamide stain coatings against self-loosening. Adjustable feet with covered threads prevent binding. Standardization ensures that spare parts are readily available. This highlights a spectrum of issues. High-quality components are more expensive to purchase, but at the same time they reduce unplanned downtime and maintenance costs. Those who only look at the purchase price often make the wrong decision.
Many sustainable effects do not arise from new materials, but from better design. For example, lightweight construction reduces energy consumption, durable materials extend the life cycle, and hygienic design shortens cleaning times and reduces the use of water and chemicals. Another lever lies in minimizing waste through the targeted use of sensors.
packaging journal 4/2026
This article was published in packaging journal 4/2026 (September).
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