Molding New Packaging Ideas With Plastic Parts Manufacturer

Need for new packaging ideas leads to Sharp Max Plus® boost in efficiency

A complex plastic parts manufacturer for the healthcare, consumer and electronics markets used a hand-counting and hand-loading system. The hand-loading system was inefficient and time-intensive, with inherently higher labor costs and not to mention the potential for errors. The manufacturer contacted IPS Packaging searching for new packaging ideas and a viable alternative to help solve their problem.

IPS Packaging suggested the Sharp Max Plus® system, with integrated thermal imprinter and automatic weigh counter, elevated the process from semi-automatic to fully automated. In the first step – opening the bag – a three-point verification system monitors success. First, the machine uses a puff of air to open the bag. It senses whether the bag has opened; if not, it inserts a funnel to mechanically open the bag on the second try. Again it checks whether a bag is present and open. If not, it presents a new bag and starts again. The system can be set to the desired number of tries before human intervention is needed. After the bagging system identifies the open bag it then counts and places the correct amount of product in the bag and continues down the line.

Packaging Issues

A manufacturer of complex plastic parts for health care, consumer and electronics markets used a hand-counting and hand-loading system.

  • Inefficient and time-intensive hand-loading system
  • High labor costs
  • Increased errors

Packaging Ideas & Solutions

Packaging Ideas Lead To The Sharp Max Plus® system

  • Eliminate Errors: Ensures reliable count while filling bags
  • Efficient use of time: Greatly decreased labor costs

Packaging Success

The Sharp Max Plus ensures a reliable count while filling bags. It can either weigh-count or optically count the injection-molded pieces being dropped into the bag. In the case of this customer, a reliable weight count was crucial. Sharp’s system is the only one in the marketplace that can achieve this weight-count level of precision. Replacing the former process of hand loading, the Sharp Max Plus uses robotic arms to drop the mold(s) into the bag.

The thermal imprinting capability of the Sharp Max Plus allows direct printing onto the bag of all verification codes and barcodes necessary for traceability. An onboard PC allows the operator to pull up various jobs, create labels, and keep a history of events within each account for maintenance, record-keeping, and tracing human or machine error. These packaging ideas have become standard in the marketplace as packaging automation and the packaging integration process continue to lower labor costs and eliminate costly errors. Furthermore, thanks to the use of many standard parts and off-the-shelf components, this customer easily added options to fit the situation.

We serve the injection molding market with several types of bags

  • Sharp Packaging High Density white opaque-to-clear
  • Clear co-extruded film
  • Gamma film

By listening closely to this customer’s needs, our packaging ideas provided a customized yet highly standardized bagger. Productivity at this manufacturer increased by 23%, and labor decreased by 40%.


Case Study Image

Customized bagger increased this manufacturer’s productivity by 23%, and lowered labor costs by 40%.

Total Packaging Cost Summary:

  • Productivity – Increase 23%
  • Labor Cost – Decreased 40%



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Posted in Bags, Poly & Plastic Case Studies, Case Studies