A packaging system integrator coordinates equipment, controls, automation, material flow, and production requirements into a complete, synchronized system.

This can include:

• • Fillers, cappers, labelers and other packaging equipment
  • Conveyors, accumulation and product handling
  • Robotics and end-of-line automation
  • Controls architecture and machine communication
  • Vision, inspection, coding and track & trace
  • Integration with new and existing equipment
  • Line balancing and throughput optimization
  • Validation, commissioning and startup stabilization

The goal is to ensure the entire system works together reliably—not simply that each individual machine operates on its own.

Engaging a system integrator early can help when:

• • Planning a new packaging line or production expansion
  • Adding new equipment to an existing line
  • Throughput or OEE is below expectations
  • Changeovers are inconsistent or time-consuming
  • Micro-stops, bottlenecks, or transfer issues affect production
  • Automation, inspection, or traceability requirements are changing
  • Existing equipment needs to be upgraded or repurposed

Early involvement helps identify integration risks, optimize system design, and make better-informed capital decisions.

OEE improvements often come from identifying and addressing the small inefficiencies that accumulate across an entire packaging line. These can include:

• • Transfer and product-handling optimization
  • Accumulation and line balancing
  • Repeatable, simplified changeovers
  • Controls and machine synchronization
  • Inspection and reject logic optimization
  • Identification of recurring micro-stops and bottlenecks

Aesus evaluates the complete line to identify bottlenecks, recurring stops, changeover issues, and integration challenges that may be limiting overall performance.

Performance improvements depend on the equipment, application, current line condition, and the underlying causes of production losses. Depending on the system, opportunities may include:

• • Reduced unplanned downtime and recurring micro-stops
  • Faster, more repeatable changeovers
  • Improved product transfers and line balance
  • Better machine-to-machine synchronization
  • Faster ramp-up and more stable production
  • Increased throughput and equipment utilization

A system assessment helps identify where improvements can realistically be made and which changes will provide the greatest operational benefit.

Aesus supports projects ranging from individual equipment upgrades and integration projects to complete turnkey packaging systems.

Projects may include:

• • Single-machine integration
  • Equipment refurbishment and modernization
  • Controls and automation upgrades
  • Robotics and end-of-line automation
  • Accumulation and product-handling improvements
  • Vision, inspection, coding and track & trace integration
  • Phased line upgrades
  • Complete turnkey packaging lines

The scope is tailored to your application, production requirements, and project objectives.

Yes. Aesus can integrate new equipment and automation with existing machinery, including equipment from other manufacturers.

Integration may include:

• • Controls and communication compatibility
  • Mechanical and product transfer evaluation
  • Throughput and line balancing
  • Conveying and accumulation modifications
  • Safety and guarding considerations
  • Legacy equipment assessment
  • Controls or automation upgrades where required

Our goal is to make new and existing equipment work together as a coordinated system while maximizing the value of your current assets.

Aesus supports a wide range of industries with packaging, automation, product handling, and system integration requirements, including:

• • Food & Beverage
  • Nutraceuticals & Supplements
  • Pharmaceutical & Medical
  • Cosmetics & Personal Care
  • Chemical & Household Products
  • Industrial & Specialty Products

Our engineering capabilities can also be applied to applications outside traditional packaging industries where automation, material handling, identification, inspection, or traceability are required.

Yes. Aesus can support customers with validation, documentation, and system design requirements for regulated production environments.

Services may include:

• IQ/OQ documentation support
• FDA and GMP design considerations
• UL and applicable safety standards
• Serialization and track & trace
• Automated inspection and verification systems
• Validation and audit-readiness support

Requirements are considered throughout the engineering and system integration process to help support the customer’s validation and compliance objectives.

Aesus provides project coordination from initial planning through installation, commissioning, and production ramp-up.

Project management may include:

• • Project scope and requirements coordination
  • Timeline and milestone management
  • Coordination of Aesus and third-party equipment
  • Customer, supplier, and internal engineering coordination
  • Controls and system integration planning
  • FAT, installation, and commissioning coordination
  • Documentation and project deliverables
  • Production ramp-up and stabilization

The goal is to keep all elements of the project coordinated and moving toward a successful production startup.

Yes.

Services include:

• • Packaging line layout design
  • Accumulation strategy
  • Space utilization planning
  • Line balancing
  • Scalability modeling

This reduces bottlenecks and protects future capacity.

Yes.

Services include:

• • Packaging line layout design
  • Accumulation strategy
  • Space utilization planning
  • Line balancing
  • Scalability modeling

This reduces bottlenecks and protects future capacity.

Duration depends on system complexity.

Ramp-up is accelerated through:

• • Pre-build validation
  • Controls testing
  • Structured startup planning
  • On-site engineering support

The goal is faster transition to rated production speed.

Yes.

Support includes:

• • Operator and maintenance training
  • Preventative maintenance programs
  • Emergency response
  • Predictive maintenance tools
  • Ongoing process optimization

These programs typically reduce unplanned downtime 5–20%.

Yes.

A structured assessment identifies:

• • OEE loss categories
  • Transfer inefficiencies
  • Accumulation imbalances
  • Changeover variability
  • Compliance gaps

Results include phased upgrade recommendations.

Provide:

• • Throughput (BPM)
  • Changeover duration
  • SKU count
  • Line layout (PDF or CAD)
  • Primary constraint

This enables faster diagnostic evaluation.

Individual machines may meet spec independently.

System integration ensures:

• • Coordinated machine communication
  • Balanced throughput
  • Predictable changeovers
  • Stable startup behavior
  • Reduced cumulative downtime

Packaging lines fail at handoffs — not typically at individual stations.