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How much time do you lose with every format changeover on your packaging line?

How much time do you actually lose with every format changeover on your packaging line? For many manufacturers, the answer slips away in small increments: a setting here, an extra check there. A new format, a smaller batch or an extra private-label variant: commercially, these are often good developments. On the shop floor, they mean more changeovers, more settings and a higher risk of errors at the same time. Especially in non-food, where products can differ widely in shape, size, weight and packaging material, the pressure often builds up at the end of the line.

That's where boxes have to be formed and closed, products grouped, labels applied correctly and pallets built up in a stable way. If one part doesn't switch over smoothly, it's not just the packaging machine that stops. The entire product flow slows down.

End-of-line today is about more than speed

Demand for flexible packaging automation is growing. Manufacturers are working with more SKUs, shorter product life cycles and more frequent format changes. At the same time, pressure on delivery times, staffing and consistent output remains high.

That's also changing the way companies look at end-of-line. According to Process & Control Today, manufacturers increasingly expect systems that not only deliver capacity, but can also be integrated with existing infrastructure, unlock production data and adapt to changing requirements. More than 60% of UK manufacturers, according to the same source, increased their investment in automation.

Regulation is also making the topic more concrete. The European Packaging and Packaging Waste Regulation (PPWR), Regulation (EU) 2025/40, has been generally applicable since 12 August 2026. The regulation sets requirements around, among other things, the sustainability, labelling and full life cycle of packaging. For manufacturers, this means packaging choices, material use and traceability increasingly need to be considered together.

Flexibility is built into the design

A flexible end-of-line solution is not simply a machine that can handle many different formats. The real gain lies in the way the line is designed and operated.

  • Fast, repeatable changeovers: settings for a product or format are stored as recipes, so operators don't have to search for the right parameters each time.
  • Tool-less or limited tool changes: operators can adjust guides, grippers or other parts without a lengthy mechanical rebuild.
  • Servo-driven movements: precise, programmable movements reduce trial and error with new formats.
  • A suitable gripper and product handling: different shapes, weights and surfaces call for a solution that prevents product damage.
  • Clear operator guidance: an intuitive interface and clear instructions reduce the risk of incorrect settings.
  • Integration between machines: transport, case packing, sealing, palletising and wrapping need to work together as a single process.

These aren't separate extras. Together, they determine how much time a format changeover really costs and how stable the line runs once it restarts.

What does this mean in practice for non-food?

Think of a manufacturer of sealants, cleaning products, personal care products or other industrial consumer goods. The primary packaging might change from a small tube or bottle to a larger version. The box dimensions change with it. The desired pallet configuration, labelling or shipping setup can also vary by customer.

A rigid line requires manual adjustments and test runs for every change. That costs production time, but it also increases the risk of incorrectly positioned products, unstable boxes or a pallet pattern that doesn't match logistics requirements.

A flexible line works differently. The operator selects the right product recipe, checks the suggested settings and starts the changeover with as little manual intervention as possible. Sensors and checks then monitor whether products are being fed, grouped and discharged correctly. This shifts the operator's role from constant fine-tuning to targeted monitoring and stepping in only when needed.

Buhmann: modular end-of-line solutions for non-food

For companies looking to make their final packaging more flexible, Buhmann offers a modular portfolio of end-of-line machines and automation solutions. The systems are used for, among other things, outer packaging, shipping cases and display cartons. Products can be grouped and loaded into different packaging formats.

The SERVOKART series forms an important basis for case packing and carton erecting. The C-series can be built around individual modules or expanded into a complete packaging line. This allows manufacturers to choose a solution that fits their current product mix, available space and desired level of automation, without losing sight of future scalability.

The SERVOKART C300, for example, combines forming or packing tray cartons with product infeed. The SERVOKART C900 goes further as a modular combination of Buhmann modules from the C- and PF-series. For more customer-specific processes, Buhmann offers the SERVOTEC X900, an individual packaging line built from functions and modules across the wider portfolio. That line can be tailored to a wide range of products and packaging formats, including boxes, cartons and blisters.

Automation around the packaging machine is also part of Buhmann's approach. Think of infeed and pick-and-place systems, robotics, case erectors, carton sealers and solutions for optimising manual workstations. The aim is not to add as much technology as possible, but to reliably connect the right process steps.

Sysmatec is Buhmann's distributor in Belgium and helps companies translate their production challenges into a suitable solution. The focus is not on a single standard machine, but on the full flow: which products need to go together in a box, which formats occur, how often changeovers happen and which packaging step causes the most downtime today.

Start with the changeover, not the machine

Anyone exploring an end-of-line solution would do well to first map out their own variation:

  1. How many SKUs and packaging formats does the line handle today?
  2. How often does a changeover happen, and how much time is lost each time?
  3. Which errors occur most often in the first few minutes after a changeover?
  4. Which formats or materials does production expect in the coming years?
  5. Where is the real bottleneck: case packing, transport, palletising or wrapping?

The answers quickly show whether speed, flexibility, ergonomics or scalability should be the first priority.

A strong end-of-line solution, then, is not the machine that reaches the highest speed today. It's the one that keeps running reliably with the next product variant too.

Want to find out where your non-food line is losing time on format changeovers? Discuss your full end-of-line packaging with Sysmatec. Together, you'll map out your current product flow, the flexibility you need and the possible automation steps.

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