MODULAR SOLUTIONS


MAKING YOUR PACKAGING LINE MORE


Mark Richards, Regional Manager at Beckhoff UK, explains how modularity can help confectionery manufacturers streamline the packaging process.


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raditionally, packaging lines have been designed for specific products and throughputs, which can be effective when working with


long production runs. However, they are also rigid. Even minor changes, like adding a new pack size or switching materials, will often require extensive reengineering which can result in downtime and added costs. In today’s fast-paced confectionery


packaging lines, agility has become key to productivity and the use of modular control system technology is a way to achieve this goal. With many packaging lines facing


increasing stock-keeping unit (SKU) counts, seasonal campaigns, and growing demand for personalised and sustainable packaging, having the ability to reconfigure lines without disruption is a distinct advantage. As packaging requirements change,


whether because of regulatory changes, material availability or changing demands, modular systems can provide a cost- effective way to be flexible. Rather than investing in an entirely new line, it is possible to swap out modules in increments which also makes it possible to extend the usable life of equipment.


Self-contained units Modular packaging lines can be treated as a series of self-contained units – for example sealers, labellers and carton erectors – all of which can be easily connected, removed and replaced when needed. Having all elements of the packaging line with simple plug-and-play capability also allows new modules to be quickly recognised by the control system with very little configuration. Modular packaging lines will be centred


around automation technologies that support the integration of individual processing units. For example, combining PC-based control systems with real-time Ethernet communication networks allows individual modules to work independently while sharing data with the central control system. One important consideration to achieve truly modular packaging lines is the use of standardised communication protocols and


24 • KENNEDY’S CONFECTION • MARCH 2026


which can further help improve uptime on busy packaging lines. Confectionery manufacturers are


AGILITY HAS BECOME KEY


TO PRODUCTIVITY AND THE USE OF MODULAR CONTROL SYSTEM TECHNOLOGY IS A WAY TO ACHIEVE THIS GOAL


also under pressure to reduce waste, lower energy consumption and use more sustainable materials, like biodegradable and recyclable packaging. Making these changes can also be challenging when using traditional fixed lines, where even small material substitutions can require system redesigns. Sealing temperatures, cutting tolerances and product handling may all need adjusting, which can result in downtime and material waste during setup. Taking a modular approach can offer


open control architectures. Together, these can enable interoperability across different equipment suppliers and, therefore, can help confectionery manufacturers scale their packaging lines more easily. Avoiding vendor lock-in makes it possible to upgrade and modify different sections and parts of the line without needing to redesign the entire control infrastructure. It’s not just about flexibility, however.


This level of automation also supports predictive maintenance, remote diagnostics and centralised monitoring,


a more agile solution. Targeted upgrades – for example replacing just a sealing or forming module to accommodate new materials such as recyclable films – can avoid the need to scrap entire systems. It also allows for the phased implementation of greener packaging options. Confectionery manufacturers need to be willing to adapt if they hope to keep up with fast-changing consumer demand, regulations and attitudes towards packaging materials. By going modular and adopting a ‘plug and produce’ approach, this can be achieved incrementally and cost-effectively.


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