Automated packaging line: Maximizing efficiency at ELIS PAVAJE | Case Study

Elis Pavaje, a Romanian company with a nationwide presence in the exterior landscaping market, has undergone significant growth.

To further optimize operations, they implemented a fully automated packaging line provided by Mach.

This has significantly increased efficiency, reduced waste, and streamlined daily operations.

About Elis Pavaje

A 100% Romanian company, Elis Pavaje was founded in 1991 in Petrești, Alba County, and is owned by the Goța brothers, Vasile and Emil. 

With a comprehensive system of products and services covering all stages of the landscaping process - from the production of vibrated pressed concrete prefabricates, consulting and design to transportation, installation and maintenance of paving - Elis Pavaje is the trusted partner for the development of any type of project.

Since 2017, the company has also offered general contracting services for infrastructure and exterior landscaping works. Currently having five production units with a capacity of 23,000 square meters of paving per day, Elis Pavaje products are available throughout the country through an extensive distribution network.

The Opportunity: Automating the Packaging Process

With a 20 million euro investment, the new factory in Arad becomes the company's largest production unit, with a technological production capacity of 7000 square meters of pavers per day. With such capacity and a constant focus on product quality, Elis Pavaje needed to complement its production line with packaging equipment that would ensure maximum protection during transportation or storage and that would easily integrate into the operational flow.

The solution: A state-of-the-art automated packaging line provided by Mach

The requirements for the new production unit in Arad were clear: the suitable equipment had to be flexible, robust, easily integrable into the production flow, and capable of operating in a specific environment, namely a dusty, low-humidity environment.

After a detailed market analysis, Elis Pavaje chose to collaborate with Mach, a top integrator with extensive experience in implementing complex industrial projects.

The solution proposed by Mach specialists, after a careful analysis of the factory's process particularities, consisted of a fully automated strapping line, developed in collaboration with the Italian partner Messersi, renowned for its industrial automation systems.

Messersi is an Italian company that designs and produces industrial automation systems with machines and packaging lines for every end of line, in any industrial and logistic sector, for any goods and packaging, worldwide.

The main features of the solution, which were the basis for the decision, included:

• Advanced technology: The automated line offers innovative functionalities that surpass traditional solutions.
• Adaptability: The system integrates perfectly into the existing production flow, even in a dusty and low-humidity environment.
• Increased efficiency: The technological contribution is designed to significantly reduce waste and improve daily processes.

Implementation of the solution: An integrated approach 

The automated packaging line implemented at Elis Pavaje is a complex system composed of four main pieces of equipment, each with a specific role in optimizing the packaging process:

• Interlayer application equipment: This can apply various types of film or mesh between layers of products, providing additional protection and stability.
• Topsheet application equipment: This applies a protective film to the top of the pallet, protecting against dust and moisture.
• Horizontal strapping equipment: This ensures the structural stability of the pallet by horizontally strapping it with polypropylene (PP) or polyethylene (PET) bands.
• Vertical strapping equipment: This completes the packaging process by vertically securing the products on the pallet with polypropylene (PP) or polyethylene (PET) bands.

These equipment items were selected for their durability, energy efficiency, and ease of maintenance.

An Optimized Packaging Process

The workflow of the automated packaging line is optimized for efficiency. The pallet loaded with products travels along a conveyor, going through the following stages:

1. Topsheet application: The pallet is fed into the topsheet device, which applies a polyethylene protective film to its upper part.
2. Horizontal strapping: After applying the top protection, the pallet advances to the horizontal strapping equipment, where it is secured with polypropylene (PP) or polyethylene (PET) strapping band.
3. Vertical strapping: The pallet advances to the vertical strapping equipment, for added stability.
4. Pallet release: At the end of the process, the fully stabilized pallet can be removed from the conveyor for delivery or storage.

Results: Improved operational performance

The implementation of the automated packaging line has generated numerous benefits for Elis Pavaje:

• Increased efficiency: Downtime is minimized, and equipment maintenance is simple due to easy access to spare parts.
• Reduced waste: There has been a significant reduction in PET tape waste, leading to considerable cost savings.
• Improved packaging quality: The increased stability of packaged products has eliminated the need for repackaging and reduced the risk of damage during transport.

Business Impact

• Increased productivity: The automation of the packaging process has enabled the company to respond quickly to market demands.
• Reduced operational costs: Savings from reduced waste and downtime have had a direct impact on profitability.
• Sustainability: Waste reduction has contributed to the company's sustainability goals.
• Competitive advantage: The implementation of this advanced solution has strengthened Elis Pavaje's position as an innovative leader in the exterior landscaping market.

By automating the packaging process, Elis Pavaje has not only streamlined its operational flow but has also laid a solid foundation for long-term sustainable growth.

The success of this project underscores the importance of continuous innovation and adaptability in the industrial sector.

Automating production processes is the only viable solution in an increasingly competitive and challenging environment, and adopting new technologies is a step forward in the effort to join the upward trend that other market players are already on. 

Each production unit in any industrial sector has its own characteristics and requires customized automation solutions to ensure its success.

This is the motto with which Mach's team of specialists has been successfully implementing projects for 30 years.

Discover how our innovative solutions can bring similar benefits to your business. 

Contact the Mach team for a personalized consultation and learn how you can achieve efficiency, quality, and sustainability in your operations.