In a market requiring more SKUs and smaller batches, format change flexibility has become as critical a purchasing criterion as speed. A very fast but rigid machine can block production for hours at every product change.
What "format change" means in packaging
Format change includes all operations needed to switch from one product or pack to another: replacing dies, sealing bars, centring guides, adjusting PLC parameters and seal quality testing. Change time is the time between the last good pack of the old format and the first of the new.
- Product change: same tray, different product — time 5-15 min
- Tray format change: new dies and parameters — time 20-60 min
- Film change: top and/or bottom reel — time 5-10 min
- MAP gas change: mixer recalibration — time 10-20 min
How to reduce format change times
The SMED (Single Minute Exchange of Die) methodology applied to packaging can reduce changeover times by 50-70%. The main levers are: tooling with quick-release connections, format parameters saved in the PLC and trained operators working in parallel.
- Dies with quick connections: -50% replacement time
- Stored PLC recipes: parameter loading in 30 seconds
- Pre-heating dies during previous production: -15 min
- Parallel work: 2 operators on changeover → time halved
- Standardised checklist: eliminates errors and post-change rework
How much do format change stoppages cost
A 45-minute format change on a line with 1,000 trays/hour output and €0.30/pc margin is worth €225 of lost margin per change. At 10 changes/week that is €2,250/week, about €117,000/year. Investing €10-15,000 in quick-change tooling pays back in under 2 months.
- Calculate: (hourly output × margin/pc × hours stopped) × changes/year
- EMA quick-change kit: format change reduced to < 15 min
- Multi-format PLC recipes: no manual parameter entry
How many formats does your line manage?
We analyse your production mix and configure the machine with the most suitable format change tooling.
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