Process automation

Real cases of OEE improvement through packaging automation

December 19, 2025

OEE (Overall Equipment Effectiveness) is one of the most important indicators in industry: it measures the real efficiency of a production line by combining availability, performance, and quality.
In many plants, end-of-line bottlenecks are responsible for a significant portion of efficiency losses.

Packaging automation not only speeds up processes, but also reduces downtime, errors, and resource consumption.
In this article, we show how different companies have improved their OEE thanks to IHRESS solutions, and which technical factors make the difference.

1. What OEE measures and why it is key in packaging

OEE combines three essential factors:

Availability: the time the machine is actually running.
Performance: the speed at which it operates compared to its maximum capacity.
Quality:the percentage of correct products without rework or rejection.

At the end-of-line, these values can drop due to causes such as:

Frequent manual adjustments
Downtime due to breakdowns or lack of coordination between machines
Variability in materials or packaging
Processes without digital control

Automating the line allows control and optimization of each of these three pillars.

Case 1: reduction of unplanned downtime

A company in the cosmetics sector had a semi-automatic packaging and palletizing line.
Format changes and stoppages between machines resulted in real availability of 82%.

After integrating an IHRESS automated system with centralized control:

Downtime was reduced by 45 %.
Availability increased to 95 %.
A visual alarm and diagnostics system was implemented

Result: greater operational stability and recovery of more than 3 productive hours per day.

Case 2: performance increase through line synchronization

In a food factory, speeds between case former, sealer, and palletizer were not balanced, causing accumulation and micro-stoppages

IHRESS redesigned the control logic with a master PLC and flow sensors.
Results after integration:

Overall performance +18%
Elimination of intermittent stoppages
Cycle time reduced by 12%

Result: a smoother line, without waiting times between stations and with better energy efficiency.

Case 3: quality improvement and waste reduction

An industrial SME experienced losses of film and adhesive tape due to incorrect tension and human errors in sealing.

The IHRESS solution included:

Automatic case sealers with tension control
Tape detection sensors
Wrapping machines with intelligent film adjustment

The results were clear:

Material waste reduced by 28 %.
Rejected products reduced by 15 %.
Quality OEE indicator improved up to 98 %.

Result: less material waste, greater consistency, and uniform packaging.

Case 4: energy and maintenance optimization

In a components plant, end-of-line automation reduced energy consumption and improved maintenance efficiency.
With frequency drives, standby sensors, and remote control, the company achieved:

energy savings 22 %.
Predictive maintenance with a 40% reduction in incidents
Increase in total OEE from 70% to 88%

Result: greater efficiency, fewer breakdowns, and return on investment in 16 months.

2. Key factors behind OEE improvement

Successful projects share several technical keys:

Centralized control: full coordination of machines
Automated adjustments: reduction of downtime
Data monitoring:early detection of deviations
Predictive maintenance: avoids unexpected failures
Staff training: greater autonomy in operation and diagnostics

IHRESS combines these factors in every project, adapting the solution to each plant’s reality.

Conclusion: measure to improve

OEE is not just an indicator, but a continuous improvement tool.
Packaging automation allows <measuring, controlling, and optimizing <each phase of the process.

Real cases show that investing in automation delivers fast, tangible, and sustained returns.
With IHRESS technical expertise, companies can increase productivity and reduce operating costs without compromising quality.