Efficient tray packing is a crucial process in many sectors, from horticulture to dry goods, in which precision, speed, and throughput are essential to making a positive margin. One of the main questions that our customers come to us with is ‘how to improve tray packing efficiency’, and often the focus of this is the food packaging equipment they use.

Well-optimised tray packing equipment has the power to revolutionise packhouse operations by boosting efficiency, increasing throughput, reducing waste, and minimising the risk of delays and bottlenecks. However, in many cases, the true driver of improved efficiency lies in the packaging itself. Let’s explore the key reasons why this is the case.

The Foundation: High Quality Packaging Materials

High quality materials are the foundation of tray packing efficiency. Simply put, if the packaging you use is prone to tearing, flimsy, or inconsistent in size or shape, it can slow down the process and increase the risk of errors. The risk to individual units might be low, but when multiplied over hundreds or thousands of cycles, the loss in efficiency can be significant.

Durable materials that maintain their structural integrity during packing, processing, handling and transport are ideal, such as:

Corrugated cardboard trays

These are strong, flexible, and sustainable, and make good choices for a variety of products.

Recycled plastic trays

With anti-slip coatings are sometimes used in sectors that require high hygiene standards, such as food processing and pharmaceutical manufacturing. To avoid the plastic packaging tax, packaging should contain at least 30% recycled material by volume

Compostable and biodegradable trays

These are gaining popularity in some produce-based industries, delivering environmental benefits alongside function.

 

Optimising Your Packaging For Your Tray Packing Operation

However, it isn’t just the objective quality of the packaging that makes a difference to tray packing efficiency, but how well your choice of packaging is aligned with your tray packing machines and your pack house processes.

Good packaging designs make the tray packing process quicker, simpler, and more accurate, reducing the need for readjustment and error corrections. So, when investing in packaging, consider the following features that contribute to efficiency:

Consistent dimensions and stackability

Trays that fit together and stack well will allow faster processing, particularly when using an automated system.

Easy-to-open mechanisms and perforations

These features can minimise the physical effort required from your workers when unpacking and repacking, reducing strain and increasing efficiency.

Clear labelling and visibility

Well-marked and labelled packaging, or transparent trays, can help your staff to identify products at a glance, reducing the risk of sorting errors and boosting productivity.

Vacuum seal efficiency

Packages and trays that can be sealed well allow a better ‘vacuum grip’ during pick and place operations, while improved seal integrity can reduce the risk of product damage in automated systems arising from drops.

In the food processing sector, for example, pre-portioned packages that fit comfortably into standardised trays are a proven way of reducing manual labour costs while also raising efficiency. Similarly, many businesses benefit from using colour-coded or uniquely shaped blister packaging to streamline assembly and reduce errors.

Find Out More

To find out more about our tray sealer packaging machines, pick and place case packers and other tray packing solutions, please get in touch with the team at Brillopak today!