Capability · Packaging lines

Packaging line controls & integration, end-to-end.

Form-fill-seal, converting, and web-handling lines — PLC migrations, HMI recipe refresh, vision tie-in, and throughput work delivered as one engagement. Same mechanical footprint, current vendor stack underneath.

When an OEM disappears, spares lead times stretch and the operator-interface language drifts. When a line hits a throughput ceiling, the bottleneck lives in one place and usually isn't the one the spec sheet blames. Either way — Kraytek reverse-engineers the controls and re-platforms the line under one crew, one schedule, one PO.

Talk to engineeringSee typical engagementsDownload scoping brief

Common engagements

Four typical packaging-line jobs.

Drawn from Kraytek's packaging-vertical work — no fabricated specs, no generic service-line boilerplate.

Controls

Line-controls retrofit
PLC migration on form-fill-seal, converting, and web-handling lines. Re-platform onto a current vendor stack without changing the operator-interface language your crew already runs.

Recipes

HMI recipe management
Recipe stores re-keyed to current HMI/SCADA conventions. Operator-facing screens, version history, and change control so the next SKU swap is two clicks instead of an outage.

Inspection

Vision-inspection tie-in
Inline vision systems integrated into the line PLC — reject logic, lot tracking, and rejection-cause analytics surfaced into the same HMI your operators already read.

Throughput

Throughput optimization
Bottleneck-grade instrumentation and drive tuning on the existing line. Production-rate gains documented against the asset, not against the spec sheet.

Engagement process

Audit → retrofit → commission.

Three steps, one crew, one PO. The line stays under your operation's control at every handoff — no foreign ownership of the documentation, no separate commissioning contractor.

  1. Audit
    On-site walkdown of the line: controls stack, I/O count, fault history, and the operator's day-to-day pain. Output: a ranked problem list engineering reads to write the first scope.
  2. Retrofit
    PLC, drive, HMI, and instrumentation replaced under one crew, one schedule, one PO. Mechanical footprint preserved; operator-interface language preserved.
  3. Commission
    Re-validation against 21 CFR Part 11 / OSHA where applicable. Documentation + spare-parts plan so the next decade of service stays in-house.

Cross-links

Where to go from here.

Printable scoping brief

Download the scoping brief
Bring this scoping brief into the call — a one-page printout of the engagements, deliverables, customer responsibilities, and the audit → retrofit → commission process. Hit the deep-dive CTA on the brief page, window.print() and walk in with a usable artifact.
Open the scoping brief

Capability recovery

OEM out of business on the line?
When the OEM disappears, spares lead times stretch and the operator-interface language drifts. Kraytek reverse-engineers the controls and re-platforms the line — see how the capability cuts across packaging, converting, and web-handling assets.
See OEM out of business?

Related case studies

Three line-control recoveries worth reading.

Start with the engagement closest to your asset: a line-down rebuild, a packaging-line retrofit, or an OEM-orphaned recovery.

Case study · Allen-Bradley rebuilds

Allen-Bradley line-down to line-back-up — a rebuild case study.
A packaging line, line-down, on a controls stack past end-of-life. The OEM out of business, spares on a six-week lead, and a rebuild scope that moves PLCs, drives, and HMIs onto a current vendor stack.
Read the case study

Case study · Packaging-line retrofit

Packaging-line retrofit — a controls-rebuild case study.
A form-fill-seal line with an aging controls stack, recipes drifting between SKUs, and inspection running standalone outside the line PLC. The retrofit moves PLC, HMI, and vision onto a current vendor stack.
Read the case study

Case study · OEM-orphaned recovery

Recovering controls when the OEM is gone, the in-house team is thin, and parts are obsoleted.
OEM-orphaned control system recovery — reverse-engineering, replacement-panel retrofit, and lifecycle extension delivered under one crew, one schedule, one PO.
Read the case study

Start the conversation

Talk to engineering about a packaging line.

Send the asset name, the controls stack, and the symptom. Engineering reads every submission — no sales triage, no script.

Project inquiry
Five fields. Engineering responds within one business day.

We respond within one business day. No triplicate vendor handoffs.

Prefer email?
Send engineering a note and we'll loop back within one business day.
Email engineeringkraytek-automation@polsia.app

For quick logistics (a capex number, a sample SOW, a vendor shortlist), the form is the fastest path — every question fields an answer.

For procurement-led introductions, please mention who on your team owns the spend in the "What are you trying to solve" box.

Back to home