PACKAGING
RIGHT FIRST TIME: 7 MISTAKES TO AVOID WHEN SPECIFYING YOUR AUTOMATION SYSTEM
By Andrew Ross, head of Software, Tekpak Automation F
or today’s manufacturers, automation is no longer a choice; it is a business imperative. Speeding up production times, reducing energy costs, cutting waste and relieving the staffing burden caused by the manufacturing labour crisis, it’s no wonder that in factories across the UK and Ireland, robotic systems are being installed in increasing numbers – and not just in cutting-edge industries such as automotive and medtech, but also in traditionally manual-heavy sectors like food and beverage, and packaging.
However, not all automation solutions are equal. Before investing in a robotic system, it is vital to ensure that any potential supplier understands your production needs and limitations, as oversights at this level can be costly. Here, we outline the seven key mistakes that every manufacturer should avoid when embarking on a new automation project, to make sure your installation runs smoothly from day one…
MISTAKE #1: NOT TAKING INTO ACCOUNT YOUR EXISTING EQUIPMENT
Any proposed new solution needs to easily integrate with your existing equipment, otherwise it will lead to production issues further down the line, reducing output and costing you money – essentially, creating more problems than it resolves.
A reputable supplier should want to visit your site and see for themselves the hardware and software systems that are already in place before
Simple HMIs with touch screens, intuitive menus, colour coding and clear visual cues will ensure your system can be widely used by all production staff, including operatives on the shop floor.
recommending a solution that integrates well with both. At Tekpak, we use OPC UA for our automated packaging systems, a cross-platform, secure, open- source communication standard to enable convenient data exchange between our solution and the customer’s existing equipment.
Our engineers will arrange a site visit at the start of every project to find out which signals are already in place and work these in when writing client-specific software, to ensure seamless integration from the point of installation. Make sure to have this conversation with your supplier at the start of your automation project – do not let it be an afterthought.
MISTAKE #2: NOT CONSIDERING YOUR AVAILABLE SPACE
Manufacturing facilities are busy, often crowded spaces. And this rings especially true for packaging halls. Your dream automation solution may look great on paper but if its footprint is too large for your existing layout, you’ll be left with the costly dilemma of deciding whether to increase space, remove existing equipment or rework your new automation system. We prefer to work ‘backwards’, beginning not with a proposed solution but from the starting point of the customer’s available space. This avoids logistical challenges further down the line. Ask your supplier if they offer a modular solution that can adapt to your layout constraints – not only will this keep down costs and limit installation difficulties, but it will also futureproof your operation, enabling you to increase production capacity as demand grows.
MISTAKE #3: NOT THINKING ABOUT DAY-TO-DAY USABILITY
Making sure that operatives can easily alter packaging formats and layouts is essential to the long-term success of your automation project.
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Often, an automation project is specified by a technical or engineering manager, with input from the C-suite and finance teams. Yet, on a day-to-day basis, the people using the system will be operatives on the shop floor. To ensure your shiny new set-up is not left gathering dust in the corner of a workshop, it’s essential that it is easy to operate by employees who may not have advanced coding or engineering skills, and who
Spring 2026 UKManufacturing
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