5 Common Mistakes in the Packaging Sector – and How to Avoid Them

Industrial packaging is one of the most critical stages in the finalization of a product. Responsible for ensuring protection, organization, and efficient logistics, it serves as the link between production and distribution.

However, this phase is often a bottleneck, limiting a company’s ability to scale production efficiently.

Operational errors, improper equipment selection, failures in preventive maintenance, and the absence of ongoing performance analysis are just a few of the issues that can cause significant losses.

In this article, you’ll learn about these common mistakes in detail and discover practical tips to overcome them—ensuring better results. Happy reading!

Why Is Industrial Packaging So Important?

Packaging is the process of placing products into appropriate containers to ensure protection, transport, storage, and commercialization.

Its role goes far beyond appearance or convenience. The main goal of today’s technological advancements in packaging is to ensure the product’s integrity until it reaches the end consumer.

Several key aspects make industrial packaging trends indispensable. Take a look:

• Product Protection: Packaging shields the product from impacts, climate variations, dust, and contamination—reducing damage during transportation and handling.
• Logistics Efficiency: Automated packaging optimizes space usage in warehouses and transport vehicles, and facilitates the handling, storage, and distribution of goods.
• Operational Safety: Proper packaging helps prevent accidents and ensures worker safety.
• Cost Optimization: A well-designed packaging solution reduces losses, shipping, and storage costs. Choosing the right machinery ensures a balance between protection and cost-effectiveness.
• Regulatory Compliance: Certain sectors—especially chemicals and fertilizers—must adhere to strict regulations concerning packaging dimensions, materials, and labeling.

5 Failures That Undermine the Efficiency of Industrial Packaging

Automatic packaging is essential for the advancement of the industry.

However, it remains a stage that is highly susceptible to failures—many of which directly impact operational costs. These issues often stem from poor strategic decisions or a lack of attention to basic management practices.

Below are the most common mistakes your industry should avoid:

1. Using Machines Unsuitable for the Product Type or Volume

One of the most critical failures is using equipment that is improperly sized.

Undersized packaging machines create bottlenecks and slowdowns, while oversized machines drive up costs without adding value.

In addition, generic parts may seem like a cost-saving measure, but they often fail to meet technical specifications—compromising packaging quality.

2. Lack of Employee Training and Qualification

Most companies invest in good equipment. But that alone doesn’t guarantee better results if operators aren’t properly trained.

Often, companies struggle to hire candidates with the right skills, leading to operational errors, poor adjustments, unplanned downtimes, and even workplace accidents.

This also negatively affects machine performance, productivity, and equipment longevity.

3. Lack of Preventive Maintenance

Waiting to perform maintenance only after equipment fails is a costly mistake—especially in packaging operations.

Another common error is the absence of a preventive maintenance plan. Neglecting this reduces the equipment lifespan, increases the risk of breakdowns and stoppages, and disrupts production consistency.

Without preventive care, the risk of production bottlenecks becomes constant.

4. Poorly Planned Production Layout

Did you know that around 30% of production time is lost due to transportation inefficiencies?

According to a Sebrae article, the main cause of this waste is poor arrangement of stock and machinery—in other words, a flawed factory layout.

A disorganized or poorly optimized layout leads to unnecessary movement, cross-traffic, and product buildup in the wrong areas, slowing down the entire production flow.

5. Lack of Performance Monitoring

With increasing automation, continuous improvement relies heavily on data and information.

Without tracking key performance indicators (KPIs)—such as cycle time, failure rate, line efficiency, and material consumption—it’s impossible to identify and resolve bottlenecks.

In such cases, companies operate “in the dark,” only addressing problems once they’ve already caused damage.

 And just as important as identifying these common mistakes are the consequences they bring, which can significantly impact overall performance:

• Loss of quality in packaged products;
• Increased operational and logistics costs;
• Reduced competitiveness due to delayed deliveries, customer complaints, and loss of market trust.

How to Avoid Errors in Industrial Packaging?

The errors mentioned above can compromise the performance and efficiency of industrial operations. But the good news is that they can be avoided with proper planning, investment in technology, and continuous training.

Here are the main recommendations:

Choosing the Right Solution for Your Business

Every factory has its own particularities. Therefore, investing in solutions compatible with your production profile and volume is essential.

In this context, Indumak manufactures automated machines that serve all types of activities—from simple operations to complex, high-capacity production lines.

Our equipment is the best choice, combining excellent cost-effectiveness with easy handling and outstanding performance.

Team Training

Even the best packaging machines depend on well-trained operators to achieve their maximum performance.

Therefore, it is essential to prioritize continuous training to reduce operational errors, increase productivity, optimize production, and minimize waste.

Implement Continuous Improvements

Continuously monitor the key performance indicators (KPIs) for industrial packaging:

• Productivity;
• Failure rate;
• •Cycle time.

This allows you to identify areas for continuous improvement, anticipate problems, and optimize processes based on real data.

You may even need to upgrade your packaging machine. The data will show!

Work with Specialized Suppliers

Partnering with companies that offer experience, excellent technical support, and specialized consulting is a key differentiator that cannot be overlooked.

Indumak stands out in this regard! Besides providing robust and ideal solutions for your business, we have a technical team ready to support you through every stage of the process, from selecting the machine to training your staff.

Get to Know Indumak and Avoid Errors in Industrial Packaging

As we’ve seen, poor equipment choices, lack of maintenance, and absence of monitoring directly compromise the efficiency of industrial packaging.

However, these problems can be avoided with a strategic approach and the support of reliable partners like Indumak.

We are a reference in Brazil and abroad, offering modern machines and specialized technical support to serve various industrial sectors.

With Indumak’s technology and expertise, your company reduces waste and ensures the delivery of products with maximum quality and safety.

Access our catalog now and discover the ideal solution for your business. We’re ready to help you on this journey.