Automated Packaging Equipment For Existing Manual Manufacturing Processes

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Developing and introducing new and innovative products always includes an element of risk. As a way of managing this risk and the associated negative financial impacts, many operations launch new products using manufacturing processes that rely more on manual operations than on automated equipment.

When a new product takes-off and market demand exceeds a manufacturer's capacity, decisions must be made on how to automate. When a new product fits commercially available packaging equipment, no problem. When the new product cannot be accommodated by readily available equipment, where can a manufacturer turn?

ZARPAC has been a go-to source for custom design build packaging equipment for over twenty-five years.

We have extensive experience analyzing and evaluating current manual manufacturing processes as well as primary and secondary packaging requirements, and then applying our technical know-how to create innovative, first of its kind packaging equipment. Our portfolio of custom, design build packaging machinery includes is outlined below.

Why do so many packaging equipment manufacturers say “no” to design build projects for new, first-of-its kind packaging equipment?

The answer is simple: they do not know how to do it, and because they don’t know how to do it, all they see is risk. When an equipment manufacturer sees risk around every corner it is no wonder so many say “no”.

ZARPAC dislikes and fears risks as much as anyone, but we have learned how to avoid and reduce design build risks for our customers and our business.

Our successful track record in custom design build packaging equipment is based on four capabilities that together set ZARPAC apart from the rest of the packaging equipment industry:

  • Validated, proprietary stage gate design build process
  • Extensive packaging machinery engineering and design build expertise
  • Proof of Principle (POP) Automation Lab
  • Proof of Principle testing using our POP Automation Lab

Our stage gate design build process combined with Proof of Principle testing are designed to accomplish two important things:

  1. Knock out projects that either cannot be successful or that cannot be successful at any reasonable expense, and
  2. Provide empirical proof that a proposed automation design and technology will be successful.

Both of these outcomes virtually eliminate the risk of failure before a customer invests in capital equipment. Our approach translates into “no” means “no-way” and “yes” means “we can do it”.

Using our proprietary stage gate design build processes and proof of principle (POP) testing process we find a way to say yes to approximately 50% of the projects presented to us.

When a project has positive POP test results and it has successfully navigated our stage gate process and the customer issues a purchase order, our success rate is 100%. We are proud of this track record and we appreciate the years of repeat business this performance has generated from custom design build customers.

We look forward to learning more about your challenging packaging application and to finding a way to say yes to your project.

To learn more about our custom packaging machinery design and build capabilities, please e-mail us at

ZARPAC's Portfolio Of Custom Design Build Packing Equipment
  • Custom case packers for pouches, cartons, bottles and tubs.
  • Combination case packer palletizers
  • Tandem case packers with independent operation for non-stop production
  • Custom capping systems with under-the-cap scoop placement
  • Robotic picking systems
  • Robotic de-casers and unscramblers.
  • Robotic puck loaders
  • Robotic palletizers
  • Integrated packaging systems for disposable floor mops including tub de-nesting, product loading, cleaning solution filling, tub sealing and lid application