A D Engineering – Packaging & Automation specialises in refurbishing Vertical Form Fill Seal (VFFS) machinery.
This case study examines the benefits of refurbishment over replacement, emphasising cost-effectiveness, ease of integration with existing operations, and reduced downtime.
Vertical Form Fill Seal (VFFS) machinery is crucial in the packaging industry for efficiently packaging products in pouches and bags. Over time, these machines experience wear and tear, leading to decreased performance, poor product quality, and manufacturing downtime.
When machinery begins to suffer issues or stop working altogether, businesses may consider replacing their existing equipment, but in most cases, these machines can be refurbished to a standard that is “as good as new” or “better than the new”. Choosing refurbishment over replacement is cost-effective, faster and provides an opportunity to review any potential upgrades that may benefit your machinery.
A D Engineering – Packaging & Automation has extensive experience refurbishing VFFS machinery. We have successfully helped our customers, ranging from small family-run businesses to industry-leading brands, save time and money with our VFFS refurbishment services.
Our refurbishment service follows a straightforward approach, ensuring our customers are engaged in both the progress of the refurbishment and the costs involved in bringing the machinery to working order.
Detailed Assessment: We comprehensively inspect the VFFS machinery to identify worn-out parts, areas requiring attention, any safety issues and the potential for any improvements or upgrades
Replacement of Consumable Parts: A targeted replacement of consumable components, such as seals, belts, sensors, and electrical parts, ensures that no unnecessary costs are incurred and only worn or defective parts are placed.
Structural Integrity Check: Ensuring the machine’s structural framework is sound and free from significant damage or wear.
Upgrading and Modernisation: We consult with our customers on any necessary upgrades or potential improvements to bring the machinery up to current industry standards, including software updates and mechanical enhancements.
Testing and Quality Assurance: Our rigorous testing process and final quality checks ensure that refurbished machines meet the required performance, quality and safety specifications and requirements.
Benefits of Refurbishment
Cost-Effectiveness
Refurbishment is significantly more affordable than purchasing new machinery. The primary costs involved in refurbishment are related to consumable parts and labour, which are a fraction of the cost of a new VFFS machine. A refurbishment can cost anywhere from 5% to 50% of the price of a new machine. This cost-saving can be reinvested in other business areas, enhancing operational efficiency.
Minimal Training Requirements
Since refurbished machines are updated versions of existing equipment, the need for extensive staff retraining is minimised. Operators are already familiar with the machinery’s basic mechanics and operational procedures, which reduces downtime and ensures a smoother transition back into full production capacity. This continuity helps maintain productivity and reduces the risk of errors associated with new equipment handling.
Focus on Consumable Parts
Our customer-first approach ensures that only the necessary parts are replaced or repaired, extending the life of the machinery without unnecessary expense. For example, replacing worn parts like sealing jaws, film pull belts, and cutting knives can restore the machine’s efficiency and reliability without needing a full replacement.
Sustainability
Refurbishment is an environmentally friendly option as it reduces waste and the demand for new machinery production. This practice aligns with sustainable business practices and can enhance the company’s reputation as a responsible corporate entity. We always look to recycle or refurbish parts where possible.
Reduced Lead Times
Refurbishment projects typically have shorter lead times than procuring new machinery. This quick turnaround allows companies to resume full production faster, minimising downtime and potential revenue loss.
Cost-Effectiveness: Refurbishment is significantly more affordable than purchasing new machinery. The primary costs involved in refurbishment are related to consumable parts and labour, which are a fraction of the cost of a new VFFS machine. A refurbishment can cost anywhere from 5% to 50% of the price of a new machine. This cost-saving can be reinvested in other business areas, enhancing operational efficiency.
Minimal Training Requirements: Since refurbished machines are updated versions of existing equipment, the need for extensive staff retraining is minimised. Operators are already familiar with the machinery’s basic mechanics and operational procedures, which reduces downtime and ensures a smoother transition back into full production capacity. This continuity helps maintain productivity and reduces the risk of errors associated with new equipment handling.
Focus on Consumable Parts: Our customer-first approach ensures that only the necessary parts are replaced or repaired, extending the life of the machinery without unnecessary expense. For example, replacing worn parts like sealing jaws, film pull belts, and cutting knives can restore the machine’s efficiency and reliability without needing a full replacement.
Sustainability: Refurbishment is an environmentally friendly option as it reduces waste and the demand for new machinery production. This practice aligns with sustainable business practices and can enhance the company’s reputation as a responsible corporate entity. We always look to recycle or refurbish parts where possible.
Reduced Lead Times: Refurbishment projects typically have shorter lead times than procuring new machinery. This quick turnaround allows companies to resume full production faster, minimising downtime and potential revenue loss.
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