How to Choose Packaging Machinery | 9 Key Considerations

Packaging machinery is at the heart of modern production. It can make or break your line’s performance. So, it must be right.

High-speed automated systems can outperform manual labour, but only if you pick the right equipment for your business. Imagine your packing line stopping mid-shift because an old sealer just can’t keep pace. And now your team has to clear a jammed conveyor belt. Frustrating right?

Investing in packaging machinery is a complex decision. Efficiency, cost-control, and compliance all hang in the balance. This guide covers 9 key considerations to help you choose the right packaging machines and equipment.

Let’s get started.

Choosing The Right Packaging Machinery Matters – Output ↑ Waste ↓ Quality ↑

Quality packaging machinery can dramatically boost production speed by running continuously at high throughput. Faster machinery means more product per shift, and precise machines reduce waste and errors.

When properly implemented, automated packaging systems help:

• increase throughput (output ↑)
• cut down scrap (waste ↓)
• improve finished-product quality (quality ↑)

In Australia, state governments offer rebates and incentives for energy-efficient packaging machinery, rewarding businesses that invest in greener solutions.

For a breakdown of the full variety of packaging machinery, see our 10 Types of Packaging Machines guide. It helps you match the right machine to your product and process.

Now that you see the real impact of the right machinery on your business output, let’s get into the key factors you need to consider when buying packaging machines.

9 Factors to Consider When Choosing Packaging Machinery

1. Production Capacity & Speed

This is how much product the machine can package in a given time. A higher-speed machine can boost throughput and meet peak demand.

Speed requirements depend on your production targets and product type. Advanced machines cut packaging time significantly. After all, automated packaging machinery works faster than manual methods.

For example, switching from hand wrapping to an automated pallet wrapper can secure hundreds of pallets per day instead of just dozens.

2. Flexibility & Changeover Time

Flexibility refers to how easily the machine adapts to new products or packaging formats.

Some machines are dedicated to one size or style. Whereas, others handle a variety of items. If your plant runs multiple SKUs (Stock Keeping Unit) or seasonal lines, a flexible design is crucial.

Also consider changeover time: can operators switch rolls, dies or moulds quickly? Short changeovers maximise uptime. For example, modular bagging machines or multi-size cartoners reduce downtime between runs.

3. Build Quality, Reliability & Uptime

Look for machines built with quality materials and precision engineering. A sturdy machine frame and durable parts mean fewer breakdowns.

Packaging machinery suppliers may quote an uptime percentage or MTBF (mean time between failures). Higher build quality mostly comes from reputable brands. Quality packaging machines with access to parts and service can remain efficient for years which boosts ROI.

Practically, a well-made machine runs longer between scheduled maintenance cycles which maximises uptime.

4. Line Integration & Scalability

Your new machine should fit into the existing production line smoothly. Check interfaces like conveyor height, control-system compatibility, and required footprint.

Scalability means planning for growth. Can you add more machines or handle faster output later?

For example, if you use pallet wrappers, make sure the new unit syncs with your conveyor speed and pallet size. Investing in modular, conveyor-ready machines allows easy expansion without a full line rebuild.

5. Staff Training Requirements

Even automated systems need skilled operators. Evaluate how much training your team will need for setup, operation, and troubleshooting.

We offer training or detailed manuals. Complex machines may have intuitive controls. But staff still need safety and maintenance training. Well-trained operators reduce errors and accidents.

For example, an operator should know how to adjust needle tension and change needles efficiently on a bag closing machine.

6. Maintenance Needs & Technical Support

All machinery requires regular maintenance. Check service intervals. How often must belts be replaced, bearings lubricated, or filters cleaned?

A low-maintenance design can save hours of downtime. Also consider the supplier’s support network.

For instance, Allpack Packaging Technologies provides spare parts and service across Australia. Routine tasks like cleaning, lubrication, inspections can be done by your operators. But specialist servicing like annual recalibration should be done by trained technicians.

7. Total Cost of Ownership (TCO) & ROI

Look beyond the sticker price. TCO includes purchase, installation, training, energy, consumables, and maintenance.

When buying packaging machinery, the upfront price (CapEx) is only half the story. You also pay day-to-day running costs (OpEx) such as energy, consumables and service.

To see the full picture, calculate your Total Cost of Ownership (TCO):

• CapEx (Capital Expenditure): One-off costs to purchase, install and commission the machine.
• OpEx (Operating Expenditure): Ongoing costs to keep it running:
• Labour to operate
• Electricity
• Packaging materials (film, tape, labels)
• Routine maintenance

Automated packaging systems tend to have higher CapEx but deliver lower OpEx, because they cut labour hours, reduce scrap and minimise downtime.

To quantify ROI, compare annual savings vs investment. Example ROI calculation:

Formula for your help: (ROI = (Annual Benefit – Annual Cost) ÷ Investment ×100.)

If a new machine costs $200,000 with $72,000 net annual benefit, ROI = (72,000/200,000) ×100 ≈ 36%, with payback under 3 years. Every business is different, so use your own numbers.

8. Warranty Coverage

Warranty gives peace of mind. Check the warranty length and terms. Standard warranties cover at least 1 year, while some suppliers offer extended warranties on major parts.

Understand what’s included: parts, labour, callouts?

Make sure it meets Australian consumer guarantees. For example, most good quality packaging machinery comes with a warranty of at least one year. Don’t forget packaging consumables like sealing heads, blades. See if the manufacturer covers them too.

9. Safety, Compliance & Environmental Impact

Safety should never be an afterthought. In Australia, a key machinery safety standard is AS 4024.1. Ensure your machine has guards, emergency stops, and meets WHS requirements.

Also consider environmental regulations: Australia’s packaging targets demand recyclable and waste-minimising solutions. Modern machines include energy-saving drives or support eco-friendly materials.

For example, DC motor drives use less power than older motors, reducing energy consumption.

How to Calculate Your ROI for Packaging Machinery

Calculating ROI helps justify the investment. Follow these steps:

1. List all costs: machine purchase price, installation, training, and any downtime during switch-over.
2. Estimate annual savings: include labour cost reduction, less material waste, faster throughput, and reduced shipping damage.
3. Use the ROI formula: ROI = (Net Annual Benefit / Initial Investment) × 100. Net benefit is savings minus any extra running costs.
4. Visualise payback: A simple breakeven chart (investment vs cumulative savings) shows how quickly you recoup costs.

For example, if a $150K machine saves $50K/year net, ROI = (50,000/150,000) ×100 ≈ 33% (3-year payback).

Is your packaging line holding back productivity and profits?

Upgrade Your Machinery with Advanced Packaging Solutions at Allpack Packaging Technologies

With over 30 years’ experience of helping Australian businesses, we supply high-performance packaging equipment and automated solutions for all industries.

Whether you need pallet wrappers, bag sealing and sewing machines, or complete packaging lines, our team can advise. Our locally stocked, energy-efficient machines and in-house support ensure you get the best use of packaging machinery.

Explore our range of packaging equipment

BUY NOW for better output and ROI.

FAQs About Packaging Machinery

1. What’s the average lifespan of packaging machinery?

With proper care, most machines run 10–15 years or more. High-quality industrial equipment and regular maintenance can keep packaging machines operational for a decade or longer.

2. How often should packaging equipment be serviced?

Routine maintenance is key. Daily cleaning and lubrication are common, plus regular inspections (e.g. belts, seals). An annual professional service is recommended. Cleaning, lubrication and checking parts should be done often, while technicians handle deeper maintenance.

3. Which industries use packaging machinery?

Nearly every sector that ships or stores products uses packaging machines. Examples include food & beverage, pharmaceuticals, chemicals, retail, and warehousing. For instance, distribution centers use stretch wrappers and conveyors, while food plants use automated baggers and sealers.

4. How does induction cap sealing differ from heat-seal packaging?

Induction sealing uses an electromagnetic field to bond a liner without direct contact, whereas heat sealing applies direct heat to fuse materials. Practically, induction is used for bottle or cap liners (no open flame), while heat sealers bond films or pouches. For more details, see our Induction vs Heat Seal guide.

5. Should I use manual hand wrapping or an automatic pallet wrapper?

Hand wrapping involves using stretch film by hand. It is low-cost and simple, suitable for occasional or light-duty use. Automatic pallet wrappers are much faster and consistent for high-volume operations.

6. How do I calculate ROI for new packaging equipment?

Start by estimating your current operating costs; labour, waste, maintenance, and how much those will drop with the new machine. Use ROI = (Net Annual Benefit / Initial Investment) ×100. Include benefits like reduced scrap and higher output for a complete picture. (See the ROI table above for a worked example.)