IEN: How can manufacturers who employ traditional low-tech packaging methods convert to more advanced assembly technology?
Earley: Many small and mid-size consumer goods manufacturers continue to employ low-tech and often manual packaging methods. Among these are suppliers of hand tools, housewares, jewelry items and toys. Typically, workers manually fasten these items to header cards or other packaging materials using twist ties, elastic barbs, and the like. But manual methods tend to be time consuming and labor intensive.
Because of the capital investment involved, these companies are often reluctant to convert from manual packaging methods to fully automatic systems. In these cases semiautomatic systems are a highly cost-effective alternative. With these systems, the actual fastening is done automatically, but an operator is needed to correctly position the product and packaging and to activate the fastening system. Even though an operator is needed, the labor requirements for semiautomatic systems are much lower than for manual methods.
An example is the AVERY DENNISON™ Elastic Staple™ Variable Needle System (VNS), which inserts strong, pliable Elastic Staple fasteners around targeted products, attaching them securely to cardboard or other packaging materials. The VNS can fasten a variety of items, such as the paintbrush shown in the accompanying photo. The system is faster and more accurate than manual fastening methods.
IEN: What packaging innovations can we expect to see in the future?
Earley: The trend is clearly toward more automation, especially for those consumer goods companies that continue to package manually. Semiautomatic systems will increasingly be integrated with other packaging equipment. The strategy will be to completely automate product and header card placement, in addition to fastener insertion.
When packaging a paintbrush, for example, the integrated systems of the future will automatically dispense the header card and correctly position the paintbrush, before automatically applying a fastener. No operator will be needed.
IEN: Will there be innovations involving elastic fasteners?
Earley: Fastener capabilities are certain to increase. Avery Dennison Elastic Staple fasteners, for example, come in various lengths and can package a wide range of products, but there are some limitations related to product size and weight. Future product offerings will likely include longer elastic fasteners and fasteners with greater tensile strength. These fasteners will be capable of attaching larger and heavier products than currently possible.