Written by
Miriam Ciriano
Marketing Department
Details
Miriam Ciriano

When budgeting for a new bottle unscrambler or any packaging automation equipment, most companies focus heavily on the upfront CAPEX. But an often-ignored cost factor that will directly affect your Total Cost of Ownership (TCO) is:
Spare parts consumption over the next 5 years, 10 and 15 years.

The Hidden Cost of Spare Parts in Packaging Machinery

A low-cost machine may seem attractive at first glance. But if it requires frequent part replacements, high-priced proprietary components, or long lead times for delivery, the real cost quickly escalates.

Some typical hidden costs include:

  • High wear part consumption
  • Proprietary, non-standardized components
  • Long delivery times for critical spares
  • Expensive expedited shipping during breakdowns

Key Factors to Evaluate in Spare Parts Planning:

  • Expected wear rates for key components.
    Ask for a forecast of consumables and wear parts over 1, 3, and 5 years.
  • Availability of local stock or regional warehouses.
    Especially important if your facility is in Europe or the USA.
  • Cost of critical spare parts kits.
    Compare not just initial machine cost but total spare parts cost over time.
  • Lead times for replacement parts.
    Shorter lead times mean less production risk.
  • Serviceability of parts by in-house maintenance teams.
    Machines that require factory technicians for basic part replacement = higher long-term costs.

Industry Benchmark: Proven Unscrambling Technology

Whether you are a pharmaceutical, cosmetic, food and beverage, lubricants or chemical product manufacturer, plan ahead and before choosing your bottle unscrambler or any other machine of your packaging line: request a spare parts forecasts and preventive maintenance kits cost for the next 5, 10 and 15 years. Avoid the “printer-effect”: buying a low CAPEX ( non-expensive) piece of machine and spending unexpected amount on OPEX (operational costs) in the coming years!

Final Tip

Before signing the PO, ask your supplier for a 5-year parts consumption estimate. It could save you tens of thousands of euros or dollars down the line.

Next topic: Why service and long-term technical support can make or break your packaging line efficiency.