Sharp MAX Bagger® Lowers Maintenance Costs

Ensuring effective parts packaging for customers in all industries.

One low-cost machine does the work of five people, and does it more accurately. Our customer, a supplier of jewelry components such as fasteners and beads, was using a hand-counting and hand-loading system.  This was taking several people to open the bags, count out the small pieces than place them in the bag.

Low productivity plagued the jewelry supplier. After several discussions with the company IPS Packaging suggested the company look at the Sharp MAX™ 12-inch Bagger with integrated thermal imprinter. Previously, an operator would open a bag, count pieces (such as beads) into it, close the bag and put a label on it. After learning about the Sharp MAX's capabilities to print a label right on the bag the company felt confident this might be the answer to the problems. The bagging machine also blows open the bag, counts pieces and loads them using a Batchmaster III vibratory bowl feeder, then closes the bag. This automated system runs 24/7 with just one operator.

Problem

A supplier of jewelry components such as fasteners and beads, was using a hand-counting and hand-loading system.

• Hand-counting and hand-loading system
• Low productivity
• High maintenance costs

Solution

IPS suggested the Sharp Max Bagger® system

• Sharp Max Bagger opens bag, counts pieces, loads them, and labels bags
• Productivity increased by 61%
• Accuracy of piece counts increased by 40%
• Fully automatic machine
• Saved 33% on material costs

Outcome

The fully automated capabilities of the Sharp MAX Bagger allow the operator to set up a job and then move on to other tasks. Previously, an operator would open a bag, count pieces (such as beads) into it, close the bag and put a label on it. Sharp’s MAX Bagger prints a label right on the bag. It blows open the bag, counts pieces and loads them using a Batchmaster III vibratory bowl feeder, then closes the bag. This automated system runs 24/7 with just one operator. This customer uses a 2.0 mil general purpose film with a white opaque back and clear front. Thermal imprinting of barcodes on the front creates a scannable product and allows viewing of the contents. The blending of two types of film— high density on one side and clear on the other—is a Sharp Packaging exclusive.

At IPS Packaging, we also offer a 2.0 mil high-density white film that mimics paper and provides extra strength for thermal imprinting. All of our films are co-extruded, a more advanced process which achieves application-specific properties without sacrificing performance. In the case of the other customer, the Sharp MAX 12-inch Bagger with vibratory bowl feeder was the answer as well. Compared to their previous system, which required proprietary parts, IPS Packaging's Sharp Packaging equipment uses off-the-shelf parts, which saves time and money on maintenance. Customers increase the ability to service their own baggers, and downtime is decreased. This customer also uses our 2.0 mil clear general purpose film.

The jewelry supplier previously needed five to eight people to meet its packaging requirements; now it requires just one employee for the same output. The company has saved 33% on material costs and increased productivity by 61%. Accuracy has increased versus the old system of hand-counting or weighing, and the company has seen a decrease in customer giveaways or returns.

The fully automated capabilities of the Sharp MAX Bagger allow the operator to set up a job and then move on to other tasks. Productivity is three times faster due to the system’s simplicity and ease of operation. Accuracy of piece counts has increased by 40%.