Written by
Tony Gregory
Regional Manager North America and Latam
Details
Tony Gregory

The Challenge of Integrating New Equipment into an Existing Line

Integrating a new machine—such as a bottle unscrambler, a bottle orienter, or a conveyor system—into an existing packaging line is never a plug-and-play process. Whether in food, pharmaceutical, cosmetic, or chemical industries, the complexity of incorporating high-speed machinery without interrupting production requires a structured approach.

In this guide, we address the most common integration challenges, field-proven solutions, and key recommendations based on the experience of a leading European packaging machinery manufacturer, with global know-how from installations across the USA and Latin America.

Step 1 – Check Footprint and Layout Constraints

Understand the Real Space Available

It is essential to validate the available space under real plant conditions, not only based on layout drawings. Over time, accumulated modifications—such as added platforms, cable trays, or electrical cabinets—may significantly reduce usable space.

Solutions:

  • If floor space is limited, consider installing the electrical cabinet separately from the machine.
  • Replace hinged doors with sliding doors or access hatches to reduce opening clearance.
  • Simulate operator access using 3D models or floor markings.

Step 2 – Validate Upstream and Downstream Interfaces

Synchronize Mechanical and Control Points

Integration fails when physical interfaces or timing are not properly aligned. Updated mechanical drawings, photographs, and real installation videos should be shared with the supplier of the new machine.

Checklist:

  • Ensure upstream and downstream conveyors have not been modified since the original installation.
  • Share PLC control logic, especially for air conveyor systems or puck handling solutions.
  • Include all current container formats and orientation requirements.

Step 3 – Ensure Safe Interaction Between Operators and Forklifts

Keep Personnel and Material Flow Safe

Blocking pedestrian walkways or forklift routes can create serious safety risks and lead to non-compliance with safety regulations.

Recommendations:

  • Confirm that the new machine footprint does not obstruct existing evacuation routes.
  • Use floor markings and column guards during installation.
  • Create temporary safe corridors when space is limited.

Step 4 – Review Compressed Air and Electrical Access

New machines often require additional compressed air lines, vacuum systems, or dedicated electrical circuits.

Critical checks:

  • Verify compressor capacity and air quality for gravity bottle unscramblers.
  • Review routing of new power lines and avoid crossing traffic areas.
  • Confirm proper grounding and check for electromagnetic interference with existing control panels.

Step 5 – Plan the Physical Entry of the Machine into the Building

This aspect is often overlooked, yet physical access to the facility can become a major constraint.

Key checks:

  • Dimensions of access doors and roller shutter heights.
  • Spacing between columns, mezzanines, and overhead piping.
  • If necessary, plan pre-assembly in sections or remove covers for transport.

Step 6 – Build a Task and Resource Schedule

Integration must be precisely timed to avoid production losses.

The plan should include:

  • Machine entry, installation, testing, and production ramp-up.
  • Assignment of technical teams: mechanical, electrical, and safety.
  • Booking of forklifts, cranes, lifting tools, and storage areas.
  • Use of Gantt charts or planning tools such as MS Project or Smartsheet.

Step 7 – Perform a Complete Risk Assessment

Safety and project success go hand in hand.

Items to assess:

  • Risks of tipping, electrical shock, or collision with existing equipment.
  • Definition of mitigation measures: physical guards, lockout/tagout procedures, and signage.
  • Identification of all involved personnel, from installers to operators.
  • Appointment of a Safety Officer to document and monitor compliance.

Step 8 – Guarantee SKU Compatibility During Ramp-Up

One of the most frequent failures is assuming that new equipment will handle all container formats without validation.

Recommended actions:

  • List all active SKU formats in advance.
  • Validate changeover times and orientation requirements.
  • Test each SKU during the ramp-up phase.
  • Adjust guides, sensors, or recipes in robotic bottle unscramblers as needed.
  • Involve operators early in changeover training.

Conclusion – Retrofitting with Confidence

Integrating a bottle unscrambler, a bottle orienter, or a packaging machine into an existing line is not only a mechanical task. It involves anticipating interactions, ensuring safety, adapting to site constraints, and validating every container format.

At POSIMAT, our retrofit projects across Europe and the USA follow these exact principles, ensuring that every upgrade is smooth, safe, and scalable.

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