Change Parts Protection: Extending Equipment Life in Packaging Lines

Taking care of your change parts can mean more than avoiding the cost of replacing them. This blog covers the common causes of change part damage, storage solutions that can protect from damage, and how taking care of your change parts can enhance the longevity of your machines.

What Are Change Parts in Packaging Lines

Change parts are the format-specific components that get swapped out when a packaging line switches between different container sizes, shapes, or products. 

The most common types include:

• Starwheels: Control container spacing and transfer between stations like fillers and cappers.
• Guide rails: Direct containers along conveyor paths and through machines.
• Timing screws: space and position containers at precise intervals for downstream equipment.
• Capping Chucks & Headsets: ensure smooth cap application to container
• Grippers: stabilize and control the container during capping and filling applications.

These components are precision-manufactured with tight tolerances, often within thousandths of an inch. That precision is what allows them to handle containers smoothly at high speeds without jams or damage. 

Why Do Change Parts Need Protection?

Even minor damage to a change part can create significant problems on the line. A small nick on a starwheel pocket might seem insignificant at first glance, but it can cause containers to get hung up, tip, or feed inconsistently. What starts as a tiny imperfection in the pocket of a starwheel can lead to product damage and unplanned downtime.

Replacement costs can increase quickly as well. Custom change parts from OEMs can take weeks to manufacture, and expediting your orders can come with massive costs. All the while, your line sits idle or runs at reduced capacity waiting for parts to arrive.

There's also the hidden cost of degraded performance. A slightly worn or damaged part might still function, but it could be causing subtle handling issues that reduce throughput or increase reject rates. Protecting your change parts is really about protecting your packaging machine’s overall efficiency and output.

Changeover carts from Septimatech feature custom “shadow board” cutouts or holders sized specifically for each part in a changeover set. Parts stay separated and secure during transport, and operators can see immediately if anything is missing. The mobility factor matters here, as mobile carts can stage parts right at the machine, reducing handling and transit time. Bringing parts directly to the machine on wheeled carts reduces the number of times each part gets handled. Fewer handoffs mean fewer opportunities for drops, bumps, or other damage during changeovers. Foam inserts, UHMW plastic liners, or rubberized surfaces absorb impact and prevent metal-to-metal contact. 

Best Practices for Handling Change Parts:

Beyond the storage solution for your change parts, how your operators handle parts day-to-day makes a significant difference in part lifespan. Below is a checklist you can use to ensure your operators handle Change parts correctly:

1. Clean Parts Before Returning to Storage:

Product residue, lubricants, and washdown chemicals left on parts accelerate corrosion and attract debris. A quick wipe-down before storage takes seconds but can extend part life considerably.

2. Inspect for Damage After Each Use:

A brief visual inspection of parts while stored catches nicks, cracks, or wear before parts go back onto the machine. Finding damage early means you can order replacements before the next changeover rather than discovering problems during production.

3. Use Proper Lifting and Transport Methods:

Carrying multiple parts by hand, dragging parts across surfaces, or using makeshift transport methods invites damage. Dedicated carts and proper lifting techniques protect both parts AND operators during changeovers.

4. Train Operators on Safe Handling Procedures

Consistent training ensures all shifts follow the same protective protocols. What seems obvious to experienced operators might not be clear to newer team members joining the line.

Benefits of Protecting Change Parts on Packaging Lines

Lower your Replacement Costs

Parts that are maintained and protected last longer, reducing spending on replacements and eliminating emergency orders with inflated pricing. The investment in proper storage pays for itself through extended part life.

Faster Changeover Times

Organized parts are ready to install immediately. There's no searching, no rework, and no surprises when operators go to make a format change on the line.

Reduced Unplanned Downtime

Fewer damaged parts means fewer mid-run failures. Lines stay running, and production schedules stay on track without unexpected stops for part replacement, avoiding what can amount to an average of $125,000 per hour that unplanned downtime costs manufacturing facilities.

Improved Operator Safety

Proper storage and handling reduces risks from dropped parts, sharp edges, or awkward lifting. Ergonomic carts and organized storage make changeovers safer for everyone involved in the process.