Repurposing is a popular buzzword in many spheres of life. It is used a lot in relation to online content, on Pinterest boards and in home improvement projects – think upcycled bottle lights and pallet furniture.

It is gaining traction as a theme in the industrial packaging industry too, as a strategy for deriving multi-functionality from a single asset. Grounded in modularity, this type of repurposing is about flexibility, future-proofing and reduced cost of ownership.

Unlocking cost-efficiencies through modular design

The concept of modularity is this: companies buy a core chassis and can then add modules depending on the capabilities they want from their kit. As their needs evolve, they can swap the modules to meet different performance objectives and functionality requirements. This means that rather than having to invest in an entirely new machine to realise growth, digitalisation, sustainable packaging or NPD ambitions, manufacturers can ‘repurpose’ existing plant.

The current economic climate is serving as a catalyst for this new trend. Cash is tight across all sectors. Coupled with rising interest rates, this means companies are looking to deploy the minimum CAPEX expenditure they can to achieve their business objectives. The modular approach aligns with this strategy, as it future-proofs automation investments, reduces cost of ownership, and, quite simply, allows companies to reduce capital spending by maximising their existing assets.

Advantages for all

It’s a strategy that is as applicable to small producers at it is to blue chip multinationals.

For startups, modularity offers an affordable route to expansion. The usual dilemma they face is whether to buy an entry level packaging machine that they will likely outgrow within two years, or an over-specced machine that will blow the budget but last much longer. Modularity takes away that decision. The startup can buy a basic flow wrapping or bagging machine, and then, at a later date, add an automated infeed, a label printer and an upgraded sealing system, for example.

For an established business that is already producing large volumes, the motivation behind a modular approach is the flexibility it provides. Take, for example, a snack manufacturer with a vertical form-fill-seal machine that produces pillow packs and block bottom bags. The manufacturer spots a market opportunity to launch a product in a ‘sexier’ doy pack, but cannot act on it because re-engineering of its existing machine is cost-prohibitive, and purchasing a new machine is too risky. The solution? A modular machine that is inherently designed to enable lines to switch between these different pack styles with minimal additional expenditure.

Another scenario might be that a manufacturer loses a retailer contract and has to secure replacement work. By enabling the same asset to be repurposed for different formats, styles, sizes, materials or volumes, modularity gives a company in this situation the agility to pivot quickly.

Engineering for modularity

But whilst the modules can be slotted in, removed, replaced and upgraded, modularity itself isn’t something that can be added on at a later date. It is a design fundamental and machines have to be built from the ground up to according to this principle.

There are three different layers of modularity, all of which are core pillars of PurPak’s equipment design.

Hardware & tooling: these are mechanical modules – physical applications that are added on to the chassis to upgrade the machine’s capabilities. Examples include infeeds, sealing heads, label printers and sensors.

COTS (Commercial Off The Shelf) parts: these are universal parts that are readily available to purchase rather than bespoke or manufacturer-specific. They include everything from motors and drives to control systems, protocols and interfaces. Maximising the use of COTS parts minimises cost and the risk of obsolescence. An example of this approach in action can be seen inside the electrical cabinets on PurPak’s machines. All the components within these cabinets are COTS so that users don’t have to replace the entire cabinet if certain parts become obsolete. This is in contrast to machine manufacturers who use proprietary or black box components.

Software: not every manufacturer will be ready for digitalised manufacturing, but making sure that any packaging equipment purchases are Industry 4.0-enabled will ensure that they are future-proofed. Every PurPak system is designed with inbuilt internet connectivity, enabling remote support, data reporting, analytics, condition monitoring and predictive maintenance capabilities to be harnessed at a later date.

A new mindset for an uncertain future

Manufacturers operate in an increasingly unpredictable marketplace, and cultivating a mindset that embraces this uncertainty is crucial for navigating its challenges and opportunities. That involves building resilience, anticipating risk and accepting that some areas lie outside of your control. In the sphere of packaging equipment, modularity presents a strategy for future-proofing investments in the face of uncertainties. Those who embrace modularity are buying into a model that offers the freedom to adapt to future change rather than spending a significant amount at the outset on a machine that can do everything. It is a different, more cost-effective way of covering future eventualities, and our bet is that in the future, ‘repurposing’ will become a buzzword in the world of packaging equipment.

If you’re reviewing your packaging operation and want to maximise your investment with modular equipment that grows with you, get in touch to find out how PurPak can help.