What makes packaging automation different from other industries?

Packaging automation must support high-speed operation, frequent changeovers, and integration across multiple OEM machines, making consistency and fault diagnostics critical.

Do you work with multi-OEM packaging lines?

Yes. We regularly integrate and standardise automation across packaging lines supplied by different OEMs.

Can packaging systems be upgraded without stopping production?

In many cases, yes. Phased upgrades and parallel testing can reduce downtime while modernising control systems.

How does SCADA improve packaging line performance?

SCADA systems provide line-wide visibility, alarms, trends, and OEE data, helping teams identify bottlenecks and performance losses.

Do you standardise PLC and HMI code across packaging machines?

Yes. Standardised PLC and HMI structures improve reliability, simplify maintenance, and reduce training effort.

Which automation platforms do you support for packaging operations?

We support Allen Bradley, Siemens, and Mitsubishi platforms, alongside a wide range of legacy and OEM-specific systems.

What is packaging automation?

Packaging automation uses PLCs, machine control systems and industrial automation platforms to improve packaging line efficiency, reliability and production consistency.

How does automation improve packaging line performance?

Automation improves production speed, fault diagnostics, machine coordination and operational visibility while helping reduce downtime across packaging environments.

Can legacy packaging systems be upgraded?

Yes. Legacy packaging systems can often be modernised through phased PLC, SCADA and machine control upgrades designed to minimise operational disruption.

What automation systems are used in packaging environments?

Packaging environments commonly use PLC systems, SCADA platforms, HMIs, conveyor controls and machine integration systems to support automated production lines.

Do you support packaging automation projects across the UK?

Yes. Stratos supports packaging manufacturers across the UK with automation upgrades, machine control systems, PLC programming and industrial monitoring solutions.

Packaging Automation

Industrial automation solutions for packaging environments, designed to improve throughput, support frequent changeovers, and maintain reliable line performance.

At Stratos Control Systems, we deliver standards-based packaging automation solutions that help manufacturers improve reliability, simplify maintenances, and support high-speed production environments.

From PLC programming and SCADA systems to control panel design and system upgrades, our solutions are tailored to the operational demands of packaging lines.

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Packaging Automation Built for Long-Term Performance

Packaging operations demand automation systems that deliver speed, precision and reliability throughout every shift. Frequent product changeovers, multiple machine interfaces and high production targets place significant demands on control systems, making reliability and maintainability just as important as performance.

At Stratos, we develop packaging automation solutions that combine PLC programming, machine control, SCADA systems and industrial control panels into a structured, supportable automation architecture. By focusing on consistent engineering standards and long-term maintainability, we help packaging manufacturers reduce downtime, improve fault diagnosis and keep production lines operating at peak efficiency.

Whether you're upgrading a single packaging machine or integrating an entire production line, our automation solutions are designed to support future expansion and evolving operational requirements.

Packaging Automation Challenges

Packaging operations face a range of automation challenges, including:

Downtime caused by machine control issues
Frequent changeovers and format adjustments
Inconsistent PLC and HMI standards across machines
Difficult integration between OEM equipment
Limited diagnostics and fault visibility
Ageing or unsupported PLC hardware

By addressing these issues at the control system level, we help packaging operations improve throughput and reliability.

Explore Automation Challenges

Supporting Packaging Systems Throughout Their Lifecycle

Packaging equipment must evolve as production demands change, new products are introduced and legacy hardware reaches end of life. A structured lifecycle approach helps maintain reliability while reducing the risk of costly unplanned downtime.

Stratos supports every stage of the automation lifecycle, from new control panel design and PLC programming to SCADA integration, automation fault finding, control system upgrades and electrical documentation. This enables packaging operations to modernise equipment, improve maintainability and extend the service life of existing automation assets.

How We Support Packaging Operations

Control Panel Design (AutoCAD & E-Plan)

Control Panel Design for Packaging Automation

We design and build machine control panels tailored for packaging equipment, focusing on clarity, compact layouts, and maintainability.

Control panel design (AutoCAD / E-Plan)
Machine-mounted and line control panels
Panel refurbishment and upgrades
Clear labelling and documentation

PLC & Machine Control Systems

We deliver PLC programming and machine control solutions for packaging machinery and production lines.

PLC programming and upgrades
Machine control and sequencing
Integration with drives, motion, and safety systems
Structured, supportable PLC code

HMI Development & Standardisation

Consistent HMI design improves usability and reduces operator error. We deliver operator-friendly HMIs that support fast-paced packaging environments.

HMI design and development
Standardised navigation and layouts
Clear alarms and fault diagnostics
Reduced training requirements

SCADA & Line Monitoring

We design SCADA systems that provide visibility across packaging lines, helping teams identify bottlenecks and performance issues.

SCADA system integration
Line performance monitoring and OEE insight
Alarm management and event history
Platforms including Ignition, WinCC, FactoryTalk View SE

Packaging System Upgrades & Refurbishment

We modernise packaging automation systems without unnecessary disruption.

PLC and HMI upgrades
Control panel refurbishment
Migration from obsolete hardware
Phased upgrades to maintain production

Control Panels Designed for Packaging Machinery

Industrial control panels form the foundation of reliable packaging automation. Well-designed panels simplify installation, improve fault finding and provide a scalable platform for future production requirements.

Our Control Panel Design, Build & Manufacture service delivers machine-mounted and line control panels that support high-speed packaging operations. Combined with detailed EPLAN documentation, structured labelling and comprehensive testing, our control panels help reduce commissioning time, simplify maintenance and improve long-term reliability.

Automation Platforms We Support

Stratos Control Systems primarily delivers packaging automation solutions using trusted industrial platforms:

Allen Bradley (widely used in packaging OEM equipment)
Siemens
Mitsubishi

We also support legacy and OEM-specific control systems, particularly during upgrade and standardisation projects.

Automation Platforms We Support Allen Bradley

Automation Designed for Fast-Moving Packaging Environments

Packaging automation systems must support frequent changeovers, precise machine control, and seamless integration between machines and upstream and downstream processes.

Our systems are designed to be:

Reliable at high speeds
Easy to fault find and maintain
Flexible for format and product changes
Scalable for future expansion

Our focus is on practical machine automation that keeps packaging lines running efficiently.

Packaging Applications We Support

Our packaging automation experience supports a wide range of applications, including:

Primary and secondary packaging
Cartoning, case packing, and palletising
Food and beverage packaging
Pharmaceutical and regulated packaging
Integrated production and packaging lines

Testing and Commissioning for Reliable Production

Before packaging automation systems enter production, they should be thoroughly tested to verify performance, safety and integration with surrounding equipment.

Our engineers carry out Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) to confirm PLC software, machine control logic, HMI functionality, communications and control panel operation before and after installation. This structured testing process helps minimise commissioning risks, reduces production disruption and ensures reliable operation from day one.

Common Packaging Automation Challenges We Help Solve

High-speed packaging environments place constant demands on automation systems. Frequent changeovers, multiple OEM machines and ageing control equipment can all contribute to downtime, inconsistent performance and increased maintenance costs.

Our specialist resources can help you address common packaging automation challenges:

Pressure to Increase Production Output – Discover how structured automation improvements increase throughput while maintaining reliable machine performance.
Improve Fault Finding & Maintenance Efficiency – Learn how standardised PLC programming, clearer diagnostics and accurate documentation reduce maintenance time.
Poorly Documented & Inconsistent Control Systems – Explore how consistent engineering standards simplify support across packaging lines with multiple OEM machines.
No Visibility Into Automation Systems – See how SCADA systems improve line monitoring, alarm management and operational visibility.
Modernise Without Disrupting Production – Find out how phased upgrades help modernise packaging equipment while minimising production downtime.

Whether you're improving an individual packaging machine or standardising automation across an entire production line, Stratos provides practical engineering solutions designed to improve reliability, maintainability and long-term performance.

Why Choose Stratos Control Systems for Packaging Automation

Experience with high-speed packaging machinery
Strong focus on machine reliability and fault diagnostics
Structured PLC and HMI standards
Expertise integrating multi-OEM packaging lines
Practical, site-focused engineering approach

We deliver packaging automation systems that run reliably, adapt quickly, and are easy to support.

Frequently Asked Questions

Talk to Us About Packaging Automation

Whether you are upgrading packaging machinery, improving line visibility, or standardising control systems across packaging lines, Stratos Control Systems can help.