Safe packaging: Prevent mechanical failures in industry and avoid losses

Tired of unexpected stoppages on your packaging line due to mechanical failures in the industry? Know that your company is not alone.

Production interruptions caused by these deficiencies are among the biggest challenges faced by industrial managers. These stoppages compromise delivery deadlines, create customer dissatisfaction, and erode the company’s reputation.

But did you know that, in many cases, the root of the problem lies in the low reliability of the equipment? The good news is that it’s possible to act preventively.

In this article, we’ll cover the main causes of interruptions, their impacts, and the measures to prevent them.

Enjoy the read.

Mechanical Failures in Industrial Packaging: What Are the Impacts?

A global survey of 72 large multinational companies, showed that industrial plants lose an average of 323 production hours per year due to equipment problems.

This finding is a wake-up call for companies. After all, mechanical failures in industry affect multiple areas of operations.

They go far beyond the simple need for repairs—they threaten the sustainability of the production process.

In packaging, they can result in:

• High costs: causing waste of energy, idle labor, rework, and often the need for overtime. Indirect costs are also common.
• Compromised deadlines: a breakdown can completely stop the production line, affecting the entire logistics schedule and generating penalties for delays and contract renegotiations.
• Customer trust at risk: unpredictability directly impacts customer satisfaction and loyalty, leading to loss of contracts and market share in highly competitive sectors.
• Reduced Overall Equipment Effectiveness (OEE): stoppages decrease the OEE metric, hindering full asset utilization and overall productivity.

Why do packaging machines fail?

Even as it expands, Brazil’s industrial sector is aging and experiencing slow renewal.

A groundbreaking survey by the National Confederation of Industry (CNI) shows that machines in the country are, on average, 14 years old, and 38% of them are close to or have already exceeded their ideal lifecycle.

But this is only one of the causes. Specifically in the packaging sector, there are other reasons worth highlighting:

• Obsolete or low-quality equipment: outdated machines or those made with lower-durability materials tend to fail more frequently.
• Inadequate or missing maintenance: lack of regular inspections, poor lubrication, and absence of adjustments contribute to the occurrence of failures.
• Use of non-genuine parts: although initially cheaper, they compromise performance, increase the risk of breakdowns, and often void the warranty.
• Incorrect operation of packaging machines: lack of proper training can lead to errors that accelerate component wear.
• Natural wear: parts have a limited lifespan and must be monitored preventively to control wear.

These reasons show that identifying the root cause of problems in the machines and operations is the first step to addressing them. See the details below.

How to prevent mechanical failures in industry?

Preventing failures in industrial packaging should be based on understanding the factors that compromise packaging efficiency.

From this understanding, we can follow a triad of actions and decisions that must be rigorously observed:

• Robust equipment
• Preventive maintenance
• Use of genuine parts

See the details:

Robust equipment

By investing in high-performance packaging machines with a strong market reputation, your industry reaps valuable benefits:

• Greater durability
• Operational stability
• Ease of maintenance

It is important to note that the choice should consider not only the price but also the quality of materials, built-in technology, and after-sales support.

Preventive maintenance

With regular inspections, proper lubrication, and scheduled component replacements, this measure prevents minor wear from turning into serious nonconformities.

Therefore, the maintenance plan should be structured to include well-defined schedules, checklists, and records of all activities performed.

Additionally, it is essential to follow current guidelines, such as NBR 5462, the Brazilian standard that defines key concepts of reliability, availability, maintenance, and system failure.

Applying these best practices is ideal for identifying and correcting common issues before they become serious failures, increasing both efficiency and operational safety.

Use of genuine parts

The final leg of this triad is the use of original manufacturer parts. This is one of the most effective ways to preserve the performance and safety of your equipment.

Aftermarket or low-quality parts compromise compatibility and can lead to even more costly failures in the short term. In addition, such replacements may void the equipment warranty.

Want to prevent your factory from stopping due to mechanical failures? Access our exclusive content on this topic and stay well informed:

Tips and best practices to reduce problems

We won’t generalize, but a large part of Brazilian industries still has a short-term vision of getting the most out of equipment to “produce more.” In other words, production takes priority while prevention is relegated to a secondary role.

This needs to change urgently. Adopting some best practices makes all the difference, especially given recent trends in packaging. Here’s what you can do:

• Develop and follow a detailed preventive maintenance plan;
• Invest in continuous training for operators;
• Maintain a strategic stock of genuine spare parts;
• Conduct regular inspections with checklists customized for each packaging machine;
• Monitor machine performance and identify patterns that, when they deviate from a threshold, indicate a failure;
• Document all interventions carried out;
• Evaluate the adoption of predictive monitoring technologies.

These actions are essential to increase predictability, drastically reducing the risk of unexpected stoppages.

Indumak is your ally in preventing mechanical failures

Prevention is a strategic measure for the financial and operational health of organizations.

After all, investing in the best equipment and adopting good maintenance practices is more efficient and profitable than dealing with the costs of unexpected stoppages.

In the field of industrial packaging, Indumak is your best ally. We offer complete solutions with robust, reliable, and technologically advanced equipment.

With our machines, your company has access to the largest technical assistance network in the segment, ensuring fast and specialized support.

Talk to our specialists and discover the full line of genuine parts to guarantee the maximum performance of your equipment:

Indumak offers complete services, including the largest technical support network in the product packaging segment

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