Every production line eventually reaches a tipping point where maintaining aging machinery becomes more costly than upgrading. Older packaging equipment can lead to downtime and delays due to longer lead times for spare parts, format changes, increasing sustainability requirements, and labor shortages.
OCME USA supports this transition with a full portfolio of solutions — from retrofit kits and modular upgrades to high-speed systems. Combined with 24/7 lifecycle support, choosing to upgrade your packaging equipment provides technically sound and financially strategic solutions.
Why the “Right Timing” for Upgrades Matters
Upgrading too soon can tie up valuable capital that might be better invested elsewhere. On the other hand, delaying too long can degrade overall equipment effectiveness (OEE), drive up maintenance costs, and put customer service levels at risk. Striking the right balance is essential.
OCME’s Line Information System equips managers with real-time data on OEE and system alarms. This enables them to identify when performance dips below acceptable thresholds — and when it's time to take action before productivity suffers.
Total Cost of Ownership Perspective
Total cost of ownership (TCO) accounts for far more than just the initial purchase price. It includes long-term expenses, which include:
- Energy consumption
- Labor
- Film waste
- Spare parts
- Unplanned downtime
When evaluated holistically, a detailed TCO model often reveals that investing in modern technology like the Vega HT can reduce film usage by double-digit percentages, achieve payback in under two years, and deliver sustained cost savings well beyond the initial investment.
Seven Signs Your Packaging Equipment Needs an Upgrade
| Signal |
Why It Happens |
OCME Solution |
|
Throughput Plateau |
Mechanical limits of legacy shrink tunnels or case packers |
Vega HT shrink-film packer delivers up to 450 packs per minute (ppm) to break performance ceilings. |
| Escalating Unplanned Downtime | Aging drives and PLC components increase failure risk | Spare parts and upgrade programs include preemptive phase-out plans to reduce line stoppages. |
|
Shelf-Ready Format Changes |
New SKUs require both wrap-around cartons and film multipacks | Gemini HT combi system switches between carton and film formats in minutes. |
| Labor Constraints |
Fewer skilled operators are available for end-of-line jobs |
Perseus robotic palletizer automates stacking to reduce labor dependence. |
| Sustainability Mandates | Brands are pushing for thinner, recycled, or recyclable packaging materials |
Recycled PE film case study shows verified 25% material savings without compromising pack integrity. |
| Rising Energy Bills | Older shrink tunnels lose heat during micro-stoppages |
Energy-saving curtains on Vega and Gemini models reduce thermal loss and energy consumption. |
| Data-Visibility Gaps | Legacy machines lack connectivity and real-time performance tracking |
Remote Data Monitoring system streams live key performance indicators (KPIs) to a cloud dashboard. |
OCME-Specific Upgrade Paths
Every production environment has a unique upgrade window. As a trusted packaging machine manufacturer, OCME offers multiple paths to modernization based on your equipment’s needs. These solutions are designed to maximize ROI without disrupting production.
Preventive Retrofits
When the core machine frame remains structurally sound, OCME recommends targeted retrofits to extend equipment life and improve performance. Upgrades may include servo conversion kits, electronic selection in-feeds, energy-saving tunnel doors, and the Cygnus automatic blank-feed module, eliminating manual board handling on the Altair wrap-around case packer.
Modular Line Extensions
For plants managing increasing SKU complexity, OCME offers modular line extensions that minimize disruption. Many customers integrate the Gemini HT combi system downstream of existing fillers, instantly allowing them to switch between cartons and film without expanding their production footprint. The integrated handle applicator further enhances efficiency by eliminating the need for a standalone machine and one operator.
Full Replacement for High-Speed Demands
In high-throughput environments — such as beverage converters exceeding 100,000 containers per hour — full equipment replacement is often the most efficient path forward. The Vega HT dual-lane configuration increases output to 450 ppm while the energy-saving kit maintains a stable tunnel temperature during short stops.
Calculating Financial Return
OCME packaging machine manufacturer engineers build ROI models that quantify savings across key operational areas. These models consider both direct and indirect cost reductions, including:
- Material Savings: Lower film and board usage through thinner gauges and optimized glue patterns.
- Labor Reallocation: Robotic palletizing allows skilled staff to shift from manual stacking to higher-value quality control roles.
- Spare Parts Efficiency: Standardized drives, belts, and sensors across the Vega, Gemini, and Altair platforms simplify inventory and reduce parts costs.
- Utility Reductions: Energy-saving curtains on gas-fired tunnels or insulated electric ovens significantly cut energy consumption during micro-stops.
- Avoided Penalty Costs: Improved reliability reduces the risk of missed shipments due to unexpected breakdowns.
For example, replacing a 20-year-old shrink wrapper running 60 µm film with a Vega HT system using 45 µm film typically results in breakeven within 18 months, even before factoring in additional uptime and maintenance savings.
Service Infrastructure Protects Your Investment
As a trusted packaging machine manufacturer, OCME’s service model ensures long-term reliability, performance, and ROI well beyond installation.
- 24/7 Remote Support: Delivered through a dedicated call center with response times guaranteed by your service-level agreement.
- Predictive Maintenance Tools: Embedded in the Line Information System to monitor component wear in real time and alert teams before failures occur.
- Global Network of Technicians: Each on-site technician carries machine-specific parts kits tailored to your installed configuration, ensuring they have parts kits calibrated to your exact machine build.
These support systems ensure your decision to upgrade your packaging equipment provides a long-term performance strategy backed by a documented lifecycle plan, not just a one-time purchase.
Case Histories That Demonstrate Timing
Well-timed packaging equipment upgrades deliver measurable results, especially when aligned with planned downtime, format transitions, or volume growth.
- A multinational beverage bottler replaced four legacy tunnels with two Vega HT units during a scheduled Christmas shutdown. OEE climbed from 72% to 92%, and the company reduced annual film spend by $480,000.
- Coca-Cola HBC Italia consolidated multiple SKU formats after installing Vega lines. This helped maintain premium shelf presentation while simplifying packaging operations.
- Goya Foods upgraded to OCME shrink wrapping and increased sauce line speeds to 120 ppm, achieving higher throughput without increasing footprint.
Implementation Roadmap
OCME ensures every upgrade is delivered with minimal disruption and maximum transparency. The implementation process follows a structured approach:
- Data Collection: OCME audits stoppage logs, spare parts usage, and film consumption to establish a performance baseline.
- Digital Simulation: 3D line layouts confirm conveyor routing, product accumulation, and operator accessibility before installation.
- Factory Acceptance Testing: Customer containers are tested on the new equipment under witnessed protocols to validate system readiness.
- Installation During Planned Downtime: Most retrofits are completed over a weekend, while full wrapper replacements are aligned with annual maintenance windows.
- Performance Guarantee: KPIs are written into the service agreement, activating 24/7 support if thresholds are unmet.
Choosing the Calendar Window
The “right” moment to upgrade your packaging equipment must align with business needs. Strategic planning ensures minimal disruption and maximum return on investment:
- Fiscal Q4: End-of-year slowdowns and remaining capital budgets make this an optimal time for equipment replacement.
- Before New Product Launches: Upgrades that add film or carton flexibility help validate packaging formats ahead of high-visibility marketing campaigns.
- Ahead of Sustainability Audits: Demonstrating recycled film capability positions your operations as proactive and environmentally responsible.
Aligning upgrade execution with periods of lower demand minimizes opportunity cost.
Take the Next Steps With OCME USA
Upgrading at the right time helps you stay in control and prevents unplanned downtime from setting the pace. OCME USA makes the evaluation process straightforward.
Request a no-obligation line audit to receive a tailored ROI projection model and a phased implementation roadmap. Choose the packaging machine manufacturer that delivers the technology and lifecycle services to keep secondary packaging a strategic asset rather than a hidden cost.