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Tag Archive: automated packaging

1. A Green Belt Approach to Packaging Automation 

   September 2, 2026 9:48 pm Comments Off on A Green Belt Approach to Packaging Automation 

   

   A Green Belt Approach to Packaging Automation 

   Lean Six Sigma Green Belt projects are built around one objective: identifying process inefficiencies and implementing measurable improvements that reduce waste, improve quality and increase operational performance.

   A recent project with Killer Brownie demonstrates how a data-driven packaging automation initiative can deliver measurable operational improvements while creating a scalable foundation for future growth.

    

   The Challenge: Identifying Process Waste

   Killer Brownie first partnered with TPC Packaging Solutions after meeting our team at PACK EXPO 2022. At the time, operators were manually erecting and taping boxes across multiple packaging streams. It was a repetitive process that consumed labor while introducing inconsistency.

   The initial implementation of a Wexxar Bel semi-automatic case erector standardized box preparation across five packaging lines, improving consistency and reducing manual work.

   As production volumes continued to increase, however, a new set of challenges emerged that represented classic Lean Six Sigma improvement opportunities:

   • Packaging-line downtime reaching up to 90 minutes per shift.
   • Production losses estimated at approximately $250 per minute of downtime
   • Frequent changeovers caused by multiple box sizes
   • Manual stacking and palletizing operations
   • Labor-intensive packaging processes that limited throughput

   From a Green Belt perspective, these challenges represented several forms of operational waste, including waiting, unnecessary motion, excess labor and process variation.

   Rather than treating each issue independently, Killer Brownie sought a comprehensive solution that would improve the entire packaging workflow.

    

   Applying a Green Belt Mindset

   TPC Packaging Solutions worked closely with Killer Brownie to evaluate material flow, packaging requirements, available floor space, and future production goals. Instead of recommending individual pieces of equipment, our engineering team designed an integrated packaging line focused on flexibility, efficiency, and long-term scalability.

   Solution	Continuous Improvement Benefit
   Wexxar WF30 Auto Adjust	Push-button changeovers eliminate lengthy manual adjustments between box sizes. The user-friendly setup reduces reliance on tribal knowledge.
   Span Tech & Shuttleworth Conveyors	Optimize product flow while maximizing limited floor space.
   Cantilevered Hand-Pack Station	Improves ergonomics without increasing the line footprint.
   FANUC Case Palletizer	Eliminates manual palletizing while improving consistency and throughput.

    

   Measuring the Results

   One of the defining characteristics of any Six Sigma Green Belt project is measurable improvement.

   Following implementation, Killer Brownie achieved significant operational gains:

   Metric	Before	After
   Packaging downtime	Up to 90 minutes per shift	30 minutes or less
   Labor required for 16-count tray line	26 employees	16 employees
   Throughput	Baseline	Increased by more than 25%
   Box-size changeovers	Manual adjustments	Push-button automation
   Palletizing	Manual	Fully automated

    

   Reducing Process Variation

   The Wexxar Bel Auto Adjust system also makes changeovers significantly more user-friendly. Instead of relying on manual adjustments or operator experience to configure the case erector for different box sizes, operators can select preset case dimensions and sealing requirements directly from the machine’s control panel. With the push of a button, the system automatically adjusts the machine to the selected specifications, eliminating time-consuming, tool-dependent setup.

   Presets can also be saved for future production runs, creating a repeatable process that reduces reliance on tribal knowledge and helps operators achieve consistent results with minimal training.

   From a Six Sigma Green Belt perspective, this standardization helps reduce process variation by making changeovers more consistent and repeatable, regardless of which operator is running the equipment.

    

   Building for Long-Term ROI 

   Many process improvement projects focus solely on solving today’s bottleneck. A stronger Green Belt strategy considers future performance as well.

   The packaging line was intentionally designed to accommodate multiple product configurations without requiring additional equipment investments. This flexibility allows Killer Brownie to respond to changing production requirements while minimizing future capital expenditures.

   According to Matt Tye, Director of Manufacturing at Killer Brownie, the long-term financial return could reach hundreds of thousands of dollars through reduced downtime, labor savings, and the ability to support continued business growth.

   “TPC always had our best interests in mind.”

   “I love working with the TPC team. They have been super instrumental in helping us grow.”

    

   Continuous Improvement After Installation

   Another principle of Lean Six Sigma is sustaining improvement over time.

   TPC Packaging Solutions continues to support Killer Brownie months after installation by providing ongoing technical assistance, coordinating OEM training, and responding quickly whenever operational questions arise.

   As Matt Tye explains:

   “The TPC team is transparent, approachable, easy to work with, and the knowledge and talent they have on site is second to none for me.”

   This continued partnership helps ensure the process improvements remain effective long after the equipment is installed.

    

   Your Next Green Belt Project May Be in Your Packaging Line

   When manufacturers think about Lean Six Sigma initiatives, packaging is often overlooked. Yet it frequently contains hidden opportunities to reduce downtime, improve labor efficiency, eliminate unnecessary motion, and increase throughput.

   Whether you’re pursuing a formal Green Belt project or simply looking to improve operational performance, TPC Packaging Solutions takes a consultative, engineering-driven approach to designing packaging systems that align with your continuous improvement goals.

   From reducing waste and increasing flexibility to supporting long-term scalability, our team helps manufacturers build packaging operations that are designed for measurable results.

   Ready to identify your next process improvement opportunity? Contact TPC Packaging Solutions to schedule a consultation and discover how automation can help support your Lean Six Sigma initiatives.

    

    

2. TPC Vision System Integration

   June 30, 2026 3:27 pm Comments Off on TPC Vision System Integration

   

    

   What is a Vision System

   A vision system uses cameras, lighting and software to capture and analyze images of parts as they move through production. These systems can automatically inspect products, verify placement, detect defects and make pass/fail decisions at production line speed.

   In traditional setups, inspection is often manual or limited to simple checks. But with integrated machine vision, manufacturers benefit from consistent inspection across every part, real-time quality control at production speeds, less manual labor and actionable data.

    

   From Basic Detection to Intelligent Inspection

   Today, TPC’s ALTA system is used to automate tape and adhesive application with high precision. With basic vision inspection integration, manufacturers can confidently verify tape presence without manual inspection.

   TPC Automation can also integrate more complex vision systems. Instead of just confirming presence, the system can be programed to detect exact tape placement, identify alignment issues or placement inconsistencies and verify product and tape dimensions.

   This shift transforms systems like the ALTA from a high-speed applicator into a closed-loop quality system.

    

   Powered by AI: A Smarter Setup

   Modern vision systems (like the Keyence IV4 Series used in TPC integrations) leverage built-in artificial intelligence to simplify setup and improve performance.

   For example, the IV4 series can:

   • Automatically identify objects using shape and color information
   • Detect parts even if they shift position or orientation
   • Count, classify, and differentiate items with minimal setup
   • Learn from images instead of relying solely on fixed programming

   Rather than writing complex rules, TPC’s expert engineering team can train the system using reference images. In many cases, even a small set of images is enough to establish reliable detection. Over time, the system builds a library of images, continuously improving its ability to recognize acceptable parts vs. defects.

    

   Flexible Integration for Any Application

   Vision system integration is not one-size-fits-all. Instead, our engineering team customizes each solution based on your application. TPC works with a variety of production environments and materials, we can tailor solutions based on material or substrate, speed of production and level of inspection complexity.

   Depending on your needs, we can deploy anything from straightforward presence detection to advanced defect recognition using higher-end models.

    

   Designed for Modern Manufacturing Environments

   The integrated vision system is built for flexibility on the floor. The system can operate with its own display or without a dedicated monitor. Output data can be sent to a database and accessed with the device of your choice. This allows operators, engineers or quality teams to access inspection data from wherever it’s most useful.

    

   Why TPC?

   While vision technology itself is powerful, the real value comes from how it’s implemented.

   At TPC, our engineering team goes above and beyond to design complete, application-specific solutions. From initial concept to system integration and optimization, we ensure the vision system works seamlessly with your process.

    

   The Future of Automation Is Vision-Enabled

   Automation improves speed and consistency. Vision brings intelligence and adaptability.

   By integrating AI-powered vision systems, manufacturers can move beyond basic automation into true process control and quality assurance, all in real time.

   Contact us to learn more about what’s possible with vision system integration.

3. A Smarter Approach to Linerless Print & Apply Labeling

   May 27, 2026 8:59 pm Comments Off on A Smarter Approach to Linerless Print & Apply Labeling

   Speed, accuracy, and uptime are no longer “nice to have” on today’s production floors, they’re expected. That’s where IMA Labeling’s new ZERO Linerless Print & Apply Labeler stands out. 

   ZERO was engineered for modern, high‑demand environments where every second counts. By eliminating traditional label liners, this system simplifies the labeling process while delivering high‑precision performance across long production runs.
   
   

   Why Linerless, and Why Now? 

   Linerless labeling is gaining traction as companies look for practical, low-cost ways to increase efficiency and reduce waste. Traditional pressure‑sensitive labels rely on silicone‑coated liners that must be removed, rewound and disposed of. ZERO removes that entire step. 

   With no liner to manage, labeling becomes cleaner and more predictable.

    

   Key Advantages of the ZERO Linerless Print & Apply Labeler 

   ZERO brings together speed and continuity in one integrated system: 

   • Up to 79% more labels per roll, dramatically extending roll autonomy 

   • Fewer roll changes, reducing downtime and operator intervention 

   • No liner waste, eliminating disposal and cleanup 

   • Simplified label path, improving reliability and consistency 

   • No rewinder required, streamlining system design and maintenance 

   The result is a Print & Apply solution that keeps lines running longer with fewer interruptions, especially valuable in high‑volume environments.
   
   

   Built for Performance-Critical Applications 

   ZERO is designed for operations where precision and repeatability matter most. It supports a broad range of industries, including E-commerce and logistics, food and beverage, pharmaceutical, personal care and consumer packaged goods.  

   The system prints variable coding and traceability data directly onto linerless labels and applies them accurately to products or packages (regardless of orientation) making integration into existing production lines straightforward.
   
   

   Trusted Technology Partnerships 

   At Interpack 2026, ZERO will be showcased with Zebra Technologies print engines, ensuring dependable, high‑quality print performance aligned with industrial requirements. The system was developed in collaboration with Zebra Technologies print engines using direct thermal linerless labels engineered for clean cutting.

    

   Turning Labeling Into a Competitive Advantage 

   By reducing material waste and simplifying daily operations, ZERO helps manufacturers turn labeling into a performance advantage. It’s a clear step forward for companies ready to modernize their labeling processes without sacrificing speed or accuracy. 

   If you’re exploring linerless labeling or looking to upgrade an existing Print & Apply system, ZERO represents a practical, production‑ready solution built for the realities of today’s manufacturing environments.  

   Contact us to discuss linerless Print & Apply solutions. 

4. How Pack Stations Are Reshaping End‑of‑Line Packaging 

   May 6, 2026 6:29 pm Comments Off on How Pack Stations Are Reshaping End‑of‑Line Packaging 

   

   In many different types of businesses, packaging is treated as a finishing step, something that happens after the “real work” is done. Products are made, quality‑checked, and ready to ship, only to slow to a crawl at the very end of the process. What should be a smooth exit often turns into a bottleneck.

   That slowdown is rarely caused by a single failure. More often, it’s the result of small inefficiencies piling up: manual box forming, inconsistent labeling, uneven pacing between operations, or labor shortages that make staffing predictable shifts difficult. When packaging depends too heavily on manual effort, even short delays ripple backward through the entire line.

   As manufacturers look for ways to do more with less, end‑of‑line packaging has become one of the most practical places to apply automation.

    

   The Case for Automating Packaging 

   Across the U.S., companies are investing more in packaging automation, but not always by jumping straight to fully robotic lines. Many operations still rely on hybrid setups that blend automation with human oversight, especially at the case‑packing and shipping stage.

   This is where Pack Stations fit naturally. Rather than replacing the entire line, a Pack Station improves the moment when finished products become finished shipments. It brings structure, flow, and consistency to packaging tasks that are otherwise repetitive and labor‑intensive.

    

   How Pack Stations Change the Flow of Work 

   In a manual packaging setup, operators often juggle many tasks at once. One person is forming boxes while another waits for product. Boxes stack up, labels get applied off‑line and small interruptions snowball into downtime. 

   A Pack Station redefines that experience by creating a dedicated, integrated workspace where each packaging step supports the next. Products arrive at a controlled pace. Boxes are formed automatically. Sealing and identification happen inline, without unnecessary handling or rework.

    

   What Goes Into a Modern Pack Station? 

   While no two Pack Stations are identical, most are built around the same core idea: keep products moving steadily and reduce unnecessary motion. 

   Conveyors and accumulation tables help regulate flow, so operators aren’t rushed one moment and waiting the next. Automated case formers take over the time‑consuming task of erecting boxes, adjusting easily for different sizes. Case sealers apply tape or adhesive with uniform pressure, removing guesswork from a critical step. 

   Identification is handled inline as well, either through automated labeling or direct case printing. This not only improves traceability but also eliminates the extra handling and errors that come with off‑line labeling. 

   When needed, additional protection like shrink wrapping can be added without disrupting the layout. 

   Because these components are modular, Pack Stations can evolve with the operation instead of becoming obsolete as volumes change.

    

   Automation That Supports People 

   One of the most overlooked benefits of Pack Stations is ergonomics. Manual packaging often involves awkward reaches, repetitive motions, and lifting that wears down operators over time. Those stresses contribute to injuries, fatigue and turnover. 

   Pack Stations are designed around the operator. Tasks happen at consistent heights. Movements are reduced or assisted. Repetitive actions are handled by machines, allowing employees to focus on monitoring quality and keeping the line running smoothly. 

   In one recent time study, implementing a Pack Station increased packing speed by 82%, raising output from 2.7 to 4.9 boxes per minute, without adding headcount. Gains like that matter, especially when labor is hard to find and even harder to retain.

    

   A Practical Path to ROI 

   Unlike large‑scale automation projects that require massive upfront investment, Pack Stations offer a more approachable entry point. Because they’re modular, manufacturers can automate the areas that cause the most friction first, then expand as demand grows. 

   Many facilities see returns quickly through higher throughput, reduced labor dependency, and fewer packaging errors. Just as importantly, Pack Stations help create a more stable process that’s less vulnerable to staffing challenges or minor disruptions. 

   Automation doesn’t have to be all or nothing. In packaging, incremental improvements can deliver the biggest wins.
   
   

   Where Pack Stations Make the Biggest Impact 

   Pack Stations are especially effective in environments where speed, accuracy, and flexibility matter: 

   • Contract packaging  

   • E‑commerce  

   • Food and beverage  

   • Manufacturing and assembly  

   • Shipping and receiving  

   In each case, the goal is the same: move products out the door efficiently without sacrificing quality or safety.
   
   

   Turning Packaging Into a Competitive Advantage 

   End‑of‑line packaging doesn’t have to be a constraint. With the right Pack Station, it becomes a controlled, scalable part of the operation, one that supports both productivity and the people on the floor. 

   TPC Packaging designs Pack Stations that fit real‑world manufacturing environments. Built around modular automation and long‑term reliability, these systems help manufacturers move faster today and adapt tomorrow.