At a Glance
If you’re looking to understand your case sealer’s total cost of ownership (TCO), you can’t skip over maintenance costs. However, quantifying maintenance is not so easily done. The best bet is to keep your eye on these four variables:
- Total Runtime – The longer your machine runs, the faster it will wear down.
- Build Quality – The higher quality your machine is, the better chance you have of components lasting.
- Plant Conditions – The environment your machine sits in, and the way it’s cared for, will quietly drive costs or keep them at bay.
- Cost of Downtime – Know how much downtime will cost you; the more costly it is, the greater justification for you to keep spares.
Keep your eye on these four variables, know your machine, and communicate with your vendor. That’s the best advice we can give, and your best bet for keeping total maintenance costs low.
Introduction
When you’re purchasing a new case sealer, the cost item on your mind is probably purchase price. And after that, you might be considering the cost of replacement parts or a service contract. What few buyers factor in is how much the machine on the quote is going to cost to maintain.
We’re not talking replacement parts – we’re talking runtime, build quality, plant conditions, and downtime – we’re talking the things that can’t be outlined on a quote. The two case sealer options that you’re comparing may be similar in price and specs but cost very different amounts to keep running. These running costs are the maintenance that really does impact a case sealer’s total cost of ownership (TCO).
In this article, we’ll cover:
- The daily and long-term case sealer maintenance cost
- Four variables that contribute to overall cost
- How to keep maintenance costs low
- Three best practices in case sealer maintenance
What Does Case Sealer Maintenance Usually Involve?
Maintenance for a case sealer will always vary, according to manufacturer and model. But there are a few factors that remain pretty consistent across the board. Your awareness of them can provide a good start to estimating overall costs.
Daily Maintenance
Daily maintenance for your case sealer can be done mostly visually, (we recommend) at the start of a shift. It doesn’t take any specialized skill – just knowing what to look for. This simple daily check can cover most of the preventive maintenance you need to keep your machine running soundly.
Ask yourself:
- Are the belts tracking properly? Is there any evidence of fray or damage?
- Are the air cylinders all functional?
- Is the machine clean? Are any case or sealing materials creating potential blockages?
On a tape machine:
4. Are the blades and spring tensions properly set?
On a glue machine:
5. Are the nozzles and glue system properly set?
There’s no additional tooling required, just a couple minutes dedicated to intentionally checking functions. There’s also no special magic in the “daily” figure. This run-through is simply good practice, and should be done periodically, so that there are no surprises.
For Other Recurring Maintenance
Maintenance Item
What Causes Need for Replacement
General Cost
Expected Lead-Time
Side Belts (two per machine, tape or glue)
Autopopulated Label (Mobile Only)
– Total runtime
– Belts left running
during a jam
– Tension set incorrectly
Autopopulated Label (Mobile Only)
Medium: ~$730 per belt
Autopopulated Label (Mobile Only)
Low, but needed most frequently
Tape Blades and Spring Tension
Autopopulated Label (Mobile Only)
– Wear and drift
– Faults increasing with drift
Autopopulated Label (Mobile Only)
Low, and mostly requiring simple attention
Autopopulated Label (Mobile Only)
Low
Pneumatic Components (cylinders included)
Autopopulated Label (Mobile Only)
– Total runtime
– Component quality
Autopopulated Label (Mobile Only)
Low: ~$80 per cylinder
Autopopulated Label (Mobile Only)
Low: usually shelf-stocked, commodity part
Motor or Gearbox
Autopopulated Label (Mobile Only)
– Long life of runtime
Note: these parts are rarely replaced, and usually need very little maintenance
Autopopulated Label (Mobile Only)
High: ~$1,220 per motor/gearbox
Autopopulated Label (Mobile Only)
Long
Lubrication is one maintenance point that you’ll want to check on your specific machine. Even among our own machines, the number of lubrication points differs. Rather than taking our general advice, look through your case sealer’s manual for best practices in lubrication points and maintenance intervals.
Maintenance Due to Runtime
On case sealers, speed is not usually the cause of replacement; it’s the number of hours you run the machine. The more hours the machine runs, the more maintenance its parts need. However, the actual runtime life of each component will vary. Establish runtime tracking so that you can stay on top of parts servicing and replacement.
Why Isn’t Speed a Factor?
Speed isn’t a main driver of machine maintenance, because the range of speeds a case sealer can run is generally pretty narrow. On our sealers, speeds range roughly 15 –30 cases per minute (CPM). That’s not a wide enough spread to move a maintenance interval.
Runtime tracking is one aspect of sealer maintenance that differs between semi-automatic and fully-automatic machines. The two require pretty similar upkeep overall, but the real difference shows up because:
Fully-automatic case sealers
usually have an hour meter included – making it easy to run a maintenance schedule.
Semi-automatic case sealers
are more basic, and typically don’t have tracking measures built in – you’re accountable for tracking your own runtime hours.
Maintenance Due to Build Quality
Component quality is the single greatest driver of case sealer TCO. And it’s a factor that won’t be detailed with purchase price.
Here’s how it works:
Buy a cheaper machine, with lower-quality components
It costs less at purchase, but as the years run on, maintenance costs and replacement parts climb.
Buy a more expensive, higher-quality machine
It costs more at purchase, but as the years run on, it achieves return on investment (ROI), maintenance needs are low, and each component lasts longer.
At some point in time, the lines that dictate the cost for each of these machines cross. Beyond that point, the “more expensive” machine has a lower TCO, while the “cheaper machine” becomes a thorn in your side.
Buyers often underestimate the sheer amount of time a machine can run. Douglas equipment that was built 25+ years ago is still running in some plants – those are case packers, rather than sealers, but the takeaway is the same.
A well-built machine can serve your operation for decades (and a good quality vendor will service it just the same as a machine built 3 years ago).
When the Cheaper, Simpler Machine Wins Over Quality
We are advocates for investing in high-quality machines. However, we must acknowledge that the pricier machine is not always the better choice.
Assuming that the price actually matches the quality you’re getting, there are cases that advocate for the cheaper machine. Though experts will disagree on where the line sits – it will have to be a judgment you weigh for your own operation – here are some situations that merit a think-over:
- Short-Run Packaging – A limited run, or seasonal item, that needs its own packaging, but won’t last long. That’s a surefire case for a cheaper machine.
- Low Volume Lines – This one is harder. If your line runs a volume of <100 cases per day, you might consider a cheaper machine, but you can also justify the quality choice. Here are the two most common sides to this argument:
Low Volume Lines #1
“If you hardly run the machine, put the money into the higher-quality build. It will last, and you might need it later on.”
Low Volume Lines #2
“Low volume is exactly the case for a machine that’s cheap and disposable. Less throughput, less return; it can’t pay the premium back.”
The question that resolves most dilemmas is, “How many years of real running do you need out of this machine?”
If the answer is many – perhaps an indefinite number of years – build quality is the variable to spend on. If your answer is one product, for a short, defined stretch, buy the simpler machine and plan on replacing it if needed.
Maintenance Due to Plant Conditions
Regardless of quality, no machine can forever withstand difficult plant conditions. If your machine is run in harsh conditions, it will naturally have a shorter lifespan than one that is run in a clean, gentle space.
You probably already know where your plant sits: in some facilities, you stick to the floor; in others, your shoes leave spotless.
Physical Conditions
Dust and moisture levels alter how much friction exists between the case and the machine. For some operations, a slippery conveyor is needed to prevent product from tipping. For others, a slippery conveyor leads to machine downtime, with product sliding all over the place. Temperature and humidity will affect how your products run, and in turn, how long your machine can run.
Note: Original equipment manufacturers (OEMs) should design their machines with some thought for environmental factors. At INSITE we design knowing that the machine will require some tolerance for environmental variance. Speak with your vendor to understand what your machine is built to withstand – and if your facility fits in range.
Operator Engagement
In servicing, our team has seen at least two separate instances where an operator missed that a belt was rubbing on a fixed internal component. The rubbing stripped the outer layer off the belt – remnants were laying all around the machine. The operators didn’t stop production right away, because the machine “was still running fine.”
The way your operators perceive maintenance and risk will have direct impacts on how much damage your machine takes, and how much money you’ll have to put into it. That’s why staff turnover has a line in the maintenance budget: an engaged operator enables a whole new level of productivity.
The Weight of Downtime and Spare Parts
When considering your machine’s TCO, something to understand is that downtime outweighs the cost of parts every time. In the grand scheme, parts are not noticeably expensive. An hour of downtime relates to:
- Hitting targets
- Pleasing customers
- Achieving productivity
That number is hard to account for, but bears more weight than a part replacement.
How does this fit into maintenance? Every spare parts decision is a gamble on this ratio. Keep an eye on your stock. Components that are known to wear down should stay stocked in-house, so a simple pneumatic component doesn’t cause downtime losses.
Note: At INSITE, we offer machine-specific spare parts kits. It’s an option in every customer’s package. Ask your vendor if they have supplied options for spare parts.
Lead time is where things get tricky. Long-lasting components (e.g. gearboxes or servos) often come from overseas suppliers, and can take months to arrive. That’s when preventive maintenance and provider stock become important. While some risk is necessary, gambling your uptime on a 3-month lead time is not.
The Actual Cost of a Case Sealer’s Maintenance
All of the minute details that contribute to case sealer maintenance make a big difference as years go by. The actual cost of your sealer’s maintenance – and overall TCO – begins with four variables:
- Total Runtime
- Build Quality
- Plant Conditions
- Cost of Downtime
Perhaps you came to this article looking for a simple cost number. Sorry to say, but maintenance costs are not so easily quantified. Your best bet is to know your machine, keep your eye on these variables, and stay in communication with your vendor.
Looking for a Vendor Who Values Uptime?
Give INSITE a call. Our specialists are happy to answer your questions, explain case sealer options, and walk through a maintenance plan.
