Engineering Services

Is your current operations team overloaded?

Need skilled engineering support for a packaging line project?

Have a packaging line project but not a project manager?

Need programming for a new controls system, but don’t have a programmer?

Don’t need a turn-key packaging line solution?

ZARPAC can help.

We offer a la carte engineering services for five critical types of packaging line projects:

  • Packaging Line Project Management
  • Packaging Line Design & Layouts + Conveyor and Accumulation Design
  • Packaging Line Controls & Programming
  • Onsite Engineering Resources
  • Packaging Line OEE Audits & Improvement Plans

Think of our Engineering Services as “Engineers For Hire”, sort of like a temp agency for highly skilled and experienced packaging line engineers and project managers.

For many of our customers whose staffs have been reduced, or that are dealing with retirements of their most experienced engineers, our engineering services can quickly fill the void without adding headcount.

Engineering Services projects typically range from one to eighteen months and assigned engineers will work remotely or at your facility based on your requirements.

Assigned engineers are dedicated to your project and they will remain engaged in your project until it has been completed and accepted. This approach provides an opportunity for our engineers to become part of your team, and it provides valuable continuity which will contribute to the success of the project.

One of key benefits of our Engineering Services is that assigned engineers are never on their own. They have a team of skilled engineers and project managers behind them that can assist whenever the need arises. Our customers tell us time and time again that this team support is something that no other vendor provides.

To learn more about our Engineering Services, please e-mail us at ZARPAC@ProMachBuilt.com.

ZARPAC Packaging Line Project Management services provide a dedicated on-site project manager for the duration of an assignment as well as any required engineering support services from the ZARPAC engineering team.

Zarpac Project Managers become a single point of contact for each project and they become part of the customer’s team. Assigned project managers are dedicated to your project and they will retain ownership of your project until it has been completed and accepted.

Project Management engagements typically range in duration from two to eighteen months and assigned project managers will work at your facility or remotely based on your requirements.

Typical project management assignments and deliverables include:

  • Preparing Project Action Lists
  • Preparing Project Action List Schedules
  • Tracking & Managing Project Action Lists and Schedules
  • Developing & Confirming The Product & Materials Matrix (complete listing of all containers, closures, labels and secondary packaging to run on the line)
  • Developing & Completing Best Value Equipment Evaluations (BVEE)
  • Developing or Updating Project Cost Estimates
  • Installation and Start-up Planning & Documentation
  • Developing Staffing and Management requirements
  • Operator & Maintenance Training Programs
  • Coordination & managing delivery of all containers, closures, labels and secondary packaging materials required for line design and testing
  • Coordinating vendor communications
  • Coordinating Shipping & Installation Arrangements With Equipment Vendors

The above list contains examples of common assignments and deliverables. Based on customer requirements our Project Managers have taken ownership of a wide range of additional responsibilities.

To learn more about our Project Management services, please e-mail us at ZARPAC@ProMachBuilt.com.

ZARPAC offers complete packaging line layout design and layout services that include all required conveyor and accumulation systems.

Our design and layout projects typically involve complete or partial packaging lines.

We offer a full range of design services and deliverables including:

  • Conceptual line layouts
  • Detailed line layouts
  • Line simulation modeling
  • Material flow modeling
  • Control system design
  • Mechanical & controls integration of equipment
  • PLC & HMI programming for line controls

The ZARPAC packaging line design team includes highly trained engineers and project managers specializing in fully integrated conveyor and accumulation systems. They bring engineering expertise, packaging line design tools and conveying system integration know-how to each project that our competitors simply cannot match.

ZARPAC design engineers use proven, validated packaging line design tools to configure and validate every packaging line. These tools replace the guess work and opinions used by other suppliers with validated formula-based tools that convert production line requirement inputs into practical design criteria.

Our family of packaging line design tools includes:

  • Packaging Line Performance Simulator
  • Optimized Accumulation Sizing Calculator
  • Sensor Positioning Calculator
  • Mass-flow Conveyor Optimization
  • Pressureless Combiner Sizing Calculator
  • Conveyor Motor & Gear Box Sizing Calculator

Line design and layouts, including conveyor and accumulation placement and sizing is a science, not an art, and our proprietary formula-based tools deliver accurate, consistent and on-target results.

Key outputs from these tools include precise inter-machine placement distances as well as the optimum location and sizing of related accumulation.

Our engineers started developing these tools over twenty-five years ago and since then they been used, tested, challenged, upgraded, expanded, validated and used successfully again and again.

Experience has taught us and our repeat customers that numbers, when used correctly, never lie.

To learn more about our packaging line layout and design services please e-mail us at ZARPAC@ProMachBuilt.com.

Line Controls & Programming projects are executed by teams of ZARPAC packaging equipment and packaging production line experts with extensive controls know-how.

Our Line Controls & Programming teams take ownership of each project from development of the specifications to system sign-off and hand-off. A single point of contact ensures accountability and effective communications with customer teams.

Assigned ZARPAC programming team members are dedicated to your project and they will retain ownership of your project until it has been completed and accepted. ZARPAC controls design and programming is 100% executed by ZARPAC personnel, never by third party contractors.

Line Controls & Programming engagements typically range in duration from three to four months and assigned team members will work at your facility or remotely based on project requirements.

Typical line controls and programming assignments and deliverables include:

  • Defining and Confirming Production Line Layout, Line Components and Production Specifications
  • Designing and Configuring Main Control Panel
  • Building the Main Control Panel
  • PackML compliant line PLC and HMI Programming
  • Modifying, upgrading and / or reprogramming of individual machine controls as needed
  • Coordinating Completion of Vendor Integration Spreadsheets (aka Product & Consume Spreadsheet – this includes tags for controls inputs and outputs, data signal outputs & inputs)
  • Coordinating Machine Vendor Communications
  • Preparing and Compiling Line Controls & Programming Documentation
  • Start-up Planning & Documentation
  • Operator & Maintenance Training Programs

The above list contains examples of common assignments and deliverables. Based on customer requirements our line controls and programming teams have taken ownership of a wide range of additional responsibilities.

To learn more about our Line Controls & Programming services, please e-mail us at ZARPAC@ProMachBuilt.com.

If you need to temporarily add an experienced, full-time packaging equipment engineer, controls engineer, mechanical engineer or project manager to your onsite team, ZARPAC can help.

Think of our Onsite Engineering Resources as “Engineers For Hire”, sort of like a temporary employment agency for highly skilled and experienced packaging line engineers and project managers.

In an Onsite Engineering Resource assignment one or more ZARPAC engineers join your on-site team. Their agenda is executing the assignments you give them. In essence our engineers and project managers become full-time, onsite resources for the duration of the assignment.

For many of our customers whose staffs have been reduced, or that are dealing with retirements of their most experienced engineers, our onsite engineering services can quickly fill the void without adding headcount.

Our Onsite Engineering Services also help customers fill critical technical positions that would be extremely difficult or impossible to fill locally.

Onsite Engineering Resource engagements typically range in duration from three months to five years and assigned engineers will work at your facility based on a schedule you specify.

When appropriate for long term assignments, ZARPAC personnel will relocate along with their families for the duration of the engagement.

Examples of Onsite Engineering Resource engagements include:

  • The senior electrical lead for a facility unexpectedly resigned. The customer needed a temporary electrical lead. We provided a skilled and experienced packaging line electrical lead for a six-month on-site assignment at a facility in the United States.
  • A customer experienced a spike in projects requiring mechanical engineering support. The spike was temporary, and the customer could not justify adding a fulltime mechanical engineer. We provided an experienced mechanical engineer with packaged goods manufacturing experience for a one-year on-site engagement at a facility in the United States.
  • In conjunction with the installation, commissioning and start-up of turnkey packaging lines customers will engage one or more ZARPAC engineers for extended assignments ranging from two months to five years. Extended assignments frequently involve relocation of the engineer(s) and their families.

Assigned engineers are dedicated to your facility and they will remain engaged with your facility until the assignment contract has been fulfilled. This approach provides an opportunity for our engineers to become part of your on-site team which provides valuable continuity which will contribute to the success their assigned projects.

One of key benefits of our Onsite Engineering Resources is that assigned engineers are never on their own. They have a team of skilled engineers and project managers behind them that can assist whenever the need arises. Our customers tell us time and time again that this team support is something that no other vendor provides.

To learn more about Onsite Engineering Resources, please e-mail us at ZARPAC@ProMachBuilt.com.