In industrial packaging operations, unexpected equipment downtime can disrupt production schedules and affect overall line efficiency.
When an automatic tray forming machine stops supplying the required cardboard packaging, the interruption may affect downstream processes, particularly where limited stocks of pre-formed trays are available.
For this reason, preventive maintenance should be considered an important part of managing production continuity, equipment availability and operating costs.
A structured maintenance programme helps manufacturers plan inspections, identify signs of equipment deterioration and address certain issues before they develop into larger failures.
However, effective maintenance requires more than following a generic checklist.
Different tray forming machines have different mechanical systems, feeding arrangements, control technologies and maintenance requirements.
This article explains how to approach preventive maintenance, which general equipment areas deserve attention and how manufacturers can measure the effectiveness of their maintenance activities.
The recommendations are intended as general guidance and do not replace the manufacturer’s technical documentation, safety procedures or model-specific maintenance instructions.
What Is Preventive Maintenance for a Tray Forming Machine?
Preventive maintenance consists of planned activities intended to keep equipment in suitable operating condition.
Unlike corrective maintenance, which is performed after a failure has occurred, preventive maintenance aims to identify and address selected risks before they result in equipment failure or production interruption.
For automatic tray forming machines, this may involve authorised inspections, functional checks, cleaning and monitoring of components subject to wear.
The appropriate activities depend on several factors, including:
- Machine manufacturer and model.
- Equipment age and operating history.
- Annual operating hours.
- Packaging materials and tray designs.
- Production environment and operating conditions.
- Manufacturer maintenance requirements.
A maintenance programme should reflect the actual machine configuration and application.
Not all tray formers use the same mechanical, pneumatic, electrical or adhesive systems. Applying identical procedures to different equipment without checking the relevant documentation can create unnecessary risks.
Why Is Preventive Maintenance Important in Packaging Operations?
Reducing the Risk of Unplanned Downtime
Unexpected equipment failures can interrupt packaging operations and create production delays.
Certain problems develop progressively through component deterioration, repeated operating anomalies or other observable changes.
Planned inspections can help identify signs requiring technical attention before they develop into more serious incidents.
However, preventive maintenance cannot eliminate every possible failure.
Its value lies in helping companies manage identifiable risks and improve the organisation of maintenance activities.
Supporting Consistent Tray Forming
Tray forming equipment must handle packaging blanks according to the requirements of the machine and the packaging design.
When mechanical or functional conditions move outside their intended operating parameters, problems may appear in feeding, positioning, folding or tray formation.
Appropriate monitoring can help maintenance personnel identify changes that require investigation.
The condition of the cardboard itself must also be considered, since material characteristics and blank quality can influence forming performance.
Improving Production Planning
Scheduled maintenance activities can be coordinated with planned production stops.
This helps companies prepare technical personnel, replacement components and the necessary resources in advance.
For facilities operating several shifts or working under tight production schedules, this coordination can be particularly valuable.
Managing Maintenance Expenditure
Unplanned failures can generate repair costs as well as indirect expenses associated with downtime.
A preventive approach can make maintenance expenditure more predictable.
However, excessive or poorly targeted preventive maintenance can also consume resources unnecessarily.
The objective is to balance the cost of planned activities against the probability and consequences of equipment failure.
Key Areas to Consider in a Maintenance Programme
The following categories provide a general framework for reviewing tray forming equipment.
Specific inspection procedures, intervention requirements and maintenance intervals must always follow the applicable manufacturer documentation.
1. Mechanical Components and Moving Parts
Mechanical systems are responsible for many of the movements required during the tray forming process.
Maintenance personnel may need to monitor abnormal noise, vibration, visible deterioration or other changes in equipment behaviour.
Any adjustment, lubrication or component replacement must follow the manufacturer’s instructions and be performed by authorised personnel.
Unapproved modifications may affect mechanical synchronisation, forming quality or machine safety.
2. Cardboard Feeding and Handling Systems
Reliable blank feeding is essential for maintaining a consistent supply of formed trays.
Feeding difficulties may result in interruptions or incorrectly positioned packaging blanks.
Operators should record recurring feeding problems and identify whether incidents are associated with particular packaging designs or material batches.
Before concluding that a machine component is defective, the team should verify whether the cardboard blanks meet the applicable dimensional and material requirements.
This helps distinguish equipment-related problems from material-related issues.
3. Pneumatic and Vacuum Systems
Some automatic tray formers use compressed air or vacuum systems for specific handling and machine functions.
Where these systems are present, abnormal operating conditions may affect feeding or other machine movements.
Checks and interventions must remain within the procedures and technical specifications supplied for the equipment.
Pressure settings, connections and components should not be altered without appropriate technical authorisation.
4. Hot-Melt Adhesive Systems
Certain tray forming configurations use hot-melt adhesive as part of the forming process.
For these machines, the adhesive application system is another important maintenance consideration.
Possible issues may involve adhesive feeding, application behaviour or operating conditions outside the specified range.
The maintenance programme should account for the recommendations of both the machine manufacturer and the adhesive system manufacturer.
Hot-melt equipment may involve high temperatures and other hazards, so inspections and interventions require the appropriate safety procedures.
5. Electrical and Control Systems
Machine alarms, sensors, control components and other electrical equipment should be included in authorised inspections.
Repeated alarms, intermittent faults and unexpected changes in machine behaviour should be documented.
Electrical testing, control cabinet interventions and programming changes must be performed by appropriately qualified and authorised personnel.
Safety guards, interlocks and other protective devices must never be bypassed to maintain production.
How to Develop a Preventive Maintenance Plan
An effective maintenance programme should be structured, documented and adapted to the production environment.
Step 1: Identify the Equipment
Create an equipment record containing the manufacturer’s name, model, serial number, manufacturing year and available technical documentation.
Where possible, include operating hours and the history of previous maintenance interventions.
Accurate identification is particularly important when requesting manufacturer support or ordering replacement parts.
Step 2: Review Manufacturer Requirements
The equipment manual should be the primary reference for defining maintenance activities.
Required intervals and procedures may vary according to the model, installed components and operating conditions.
A generic schedule should not replace these instructions.
Step 3: Define Responsibilities
Separate routine operator observations from technical maintenance activities.
Operators may be authorised to identify and report specific conditions, while other tasks require trained maintenance technicians or manufacturer support.
Responsibilities must reflect the organisation’s safety procedures and the instructions supplied with the equipment.
Before physical maintenance work begins, applicable energy isolation and hazardous-energy control procedures must be followed.
Step 4: Schedule Maintenance Activities
Coordinate planned interventions with production management.
The programme should identify the activity, responsible personnel, required resources and planned execution window.
Maintenance intervals should be based on manufacturer instructions and equipment criticality rather than arbitrary daily, weekly or monthly assumptions.
Step 5: Record Completed Work
Maintenance records should document what was observed, which actions were completed and whether the equipment returned to the required operating condition.
This information makes it easier to identify recurring issues and assess the effectiveness of the maintenance programme over time.
Maintenance Indicators That Help Measure Performance
Maintenance activities should be connected to measurable operational outcomes.
| Indicator | What it measures |
|---|---|
| Equipment availability | Proportion of planned operating time during which equipment is available |
| MTBF | Mean time between defined failures |
| MTTR | Mean time required to repair the failures included in the measurement |
| Unplanned downtime | Frequency and duration of unexpected interruptions |
| Recurring incidents | Problems that repeatedly affect the equipment |
| Maintenance plan compliance | Proportion of scheduled activities completed |
Common Preventive Maintenance Mistakes
Waiting Until Equipment Fails
Relying exclusively on corrective maintenance can create operational uncertainty and make it more difficult to plan resources.
A preventive programme provides a framework for addressing selected issues in advance.
Failing to Record Repeated Problems
Without reliable maintenance records, recurring faults may be treated as isolated events.
Documenting incidents helps technicians recognise patterns and evaluate possible corrective actions.
Using Unapproved Parts or Adjustments
Components and settings must be suitable for the specific machine.
Incorrect replacements or modifications may affect equipment performance, tray quality or safety.
Overlooking Operator Training
Operators should understand normal machine behaviour, recognise relevant warning signs and know how to report problems.
Training also helps clarify which observations are permitted and which interventions must be referred to qualified technicians.
Misdiagnosing Packaging Material Issues
A feeding or forming problem may result from cardboard characteristics rather than a mechanical failure.
Diagnosis should consider both the equipment and the packaging material.
Would you like to review the maintenance requirements of your tray forming equipment?
Contact Boix Maquinaria to discuss your machine model, operating conditions and available technical support options.
