It happens for different reasons. Sometimes it is a decision made by the purchasing department aimed at reducing costs. Sometimes the end customer requests less plastic. Sometimes it is compliance with new European packaging regulations, such as the PPWR Regulation. Sometimes it is all of these things combined.

Whatever the reason, when the primary film gets thinner, the package becomes lighter and more deformable.

On the conveyor, however, this means less stability.

On the conveyor, just a few microns change everything

A 28-micron film creates a very different pack from a 40-micron one. Lighter and more flexible, it is more affected by any type of contact – whether with product guides or with other packs in accumulation zones. The risk of deformation or overlapping inevitably increases.

Downstream, this results in micro-stops and scrap, and often in complaints from customers receiving damaged products.

The packaging machine continues to run as usual, but the entire section between production and packaging is no longer suitable for the new format. As a result, speeds, chain type, side guides, and contact surfaces all need to be reconsidered, because the entire conveying section must be recalibrated according to the new mechanical properties of the pack.

The buffer that worked yesterday may no longer be suitable today

An accumulation system is designed based on the real parameters of the format, such as weight, rigidity and pack dimensions. When these parameters change – for example, when switching to lighter or more flexible packaging – the behaviour of the product inside the buffer changes accordingly. In a pressure-based system, a less rigid pack therefore risks deformation or damage during accumulation if everything is not correctly set.

The MH Material Handling BAT Buffer operates without pressure on the product and is designed to be flexible and configurable across multiple formats and layouts. This makes it suitable even for lightweight and delicate packs.

However, flexibility does not mean that a single setup works for everything: if the format changes significantly and the buffer is not readjusted, the risk of jams and damage remains.

A useful rule of thumb during the design phase is that a buffer should hold between 2 and 5 minutes of production: the time needed to absorb the typical micro-stops of the line without losing productivity. With lighter formats, however, it is worth recalculating both the effective accumulation capacity and the discharge speed, considering that the downstream machine should be able to run at least 10–20% faster than average to recover the accumulated product.

Downstream of the packaging machine is where the real game is played

When package weight and rigidity change, the requirements of the downstream section of the primary packaging also change. All downstream mechanics – aligners, phases and lane combiners – are suddenly handling a product that is no longer matches the original design assumptions.

The packaging machine keeps running, but the downstream area – the one nobody actively monitors – is where efficiency is lost.

That is why every format change requires a check of the feeding and conveying systems, and it must be done before problems arise.

How to adapt the line without stopping production

The process starts with mapping the characteristics of the new package: weight, dimensions, rigidity and coefficient of friction.

The new format is then tested across every section of the line, not only on the packaging machine, because each section reacts differently and must be checked individually.

The most important step is to involve the conveyor supplier already during the design phase, not once the problem has already become evident.

Working in stages – validating one section at a time before moving on to the next – allows production to remain active while reducing risks.

The format changes. The line cannot stay the same

When a company decides to reduce packaging weight or thickness – whether to cut costs or to meet sustainability requirements – the decision usually starts in the purchasing department. A thinner film is selected, the price is negotiated, and the specification is updated in the system. And then it stops here.

The problem is that no one checks the impact of that change on the packaging line. The process engineer is not involved, at least not immediately. They are called in weeks later, when machine downtime starts to increase, scrap rises, and OEE drops without an obvious cause.

The machine is the same. The product is the same. However, the packaging has changed, and that change affects the entire line: from packaging to accumulation, from conveying to palletizing.

For over 40 years, MH Material Handling has been designing conveying and accumulation systems. We work on layout analysis, buffer configuration, feeding system adaptation, and the integration of new solutions into existing lines, ensuring everything works with today’s format, not yesterday’s.

If you are considering a format change, or if you are already facing issues after a reduction in material thickness, let’s talk before inefficiencies become the norm. A preventive technical discussion costs far less than a stopped line.

When designing a packaging line, attention immediately goes to the machines: which packaging machine to choose, what type of labelling machine to install, where to place inspection systems.

However, there is one element that determines the efficiency of the entire system even before thinking about the machines: the layout.

A well-designed layout is almost invisible. Operations flow smoothly, maintenance is quick, and operators move without obstacles.

On the contrary, a poorly designed layout makes itself felt every day, with downtime, bottlenecks, cleaning difficulties, and waste of space and time.

Many issues that seem to originate from the machines actually arise during the layout design phase.

A recurring machine stoppage at the same time every day, for example, may not be due to a technical fault, but to a buffer positioned in the wrong point of the line.

A cleaning process that takes twice as long as expected may be the result of conveyors placed too close to each other, not a surface sanitization issue.

Operators losing valuable minutes moving materials from one area of the line to another may indicate a flow design error, not a lack of staff.

The layout determines how machines interact, how materials move, and how operators work. And when the layout is wrong, even the best machines struggle to perform at their full potential.

Let’s look at the most common mistakes that compromise the performance of a food processing line.

1.   Underestimating space for maintenance and sanitation

This is one of the most frequent mistakes: machines and conveyors positioned too close to each other, without considering that they will need to be accessed for cleaning, inspection, and component replacement.

In the food industry, this becomes a critical issue, as sanitation is not an occasional activity but an integral part of daily operations.

If a conveyor belt is trapped between two machines with insufficient lateral space, cleaning becomes superficial. Operators struggle to reach critical areas, downtime increases, and hygiene risks grow.

Even the most advanced Hygienic Design loses effectiveness if the layout does not support it. An open frame designed for drainage is of little use if there is no physical space to access the surfaces to be cleaned. For this reason, it is essential to consider not only the machine itself, but also the operational space around it: the room needed to open frames, remove components, allow operators to access with cleaning equipment, and move freely during sanitation procedures.

2.   Ignoring material and operator flows

An efficient layout defines clear paths. Raw materials, semi-finished products, finished goods, and waste must each follow a precise flow, ideally unidirectional, from “dirty” to “clean”. When these flows intersect, the risk of cross-contamination increases exponentially.

The same applies to operator movement. If reaching a quality control station requires crossing the entire line and passing near the waste discharge area, there is a design flaw.

Every unnecessary movement is lost time and a potential food safety risk.

Physical separation between areas with different hygiene levels should be planned from the outset. The positioning of buffers and accumulation systems also makes a difference: a BAT Buffer placed in the right position can absorb downstream micro-stoppages without blocking the entire line. Placed incorrectly, it becomes just an obstacle.

3.   Failing to plan for flexibility in format changes and future expansion

Food processing lines are not static. Formats change, production evolves, and volumes grow. Yet many layouts are designed without considering future developments. As a result, when it’s time to introduce a new format or add an inspection station, physical constraints become a barrier. There may be no space to integrate new elements, even if the modularity of conveyors would allow it.

Modularity is not just a feature of machines—it is a design principle that should also guide layout planning.

Systems like BAT are built on this logic: standard components that adapt to different configurations.

However, the layout must also include “growth areas” identified from the beginning—spaces where buffers, additional stations, or line diversions can be added.

Planning for flexibility may involve a slightly higher initial cost, but it leads to significant savings in the medium term, when production changes can be implemented in hours instead of weeks of downtime.

4.   Choosing the wrong accumulation system (or not including one at all)

Every line includes machines operating at different speeds. Without an accumulation system, even a micro-stoppage of a few seconds can halt the entire production flow.

Yet many layouts either do not include buffers or size them incorrectly.

An oversized buffer takes up valuable space without delivering real benefits.
An undersized buffer cannot absorb flow variations and becomes ineffective.

Then there is the choice of system type: accumulation systems with product-to-product contact can damage fragile items such as biscuits or packaged snacks, even when using low-pressure solutions.

The BAT Buffer was developed precisely to address these issues: compact, zero-pressure accumulation that ensures operational continuity even during micro-stoppages.

However, the key point is this: buffers must be planned during the layout design phase and positioned strategically—not added later as a patch once problems arise.

5.   Overlooking heights and elevation changes

It may seem like a minor detail, but operating heights make the difference between an efficient line and one that strains operators. Conveyors placed too high or too low force unnatural postures, increase the risk of errors and injuries, and slow down operations.

Height differences between conveyors must also be carefully calculated.

A sudden drop can destabilize fragile or unstable products.

In some cases, when horizontal space is limited, spiral conveyors provide an effective solution, allowing elevation changes without occupying valuable floor space.

Ergonomics becomes an investment that translates into fewer errors, fewer stoppages, and higher productivity.

And it must be considered from the layout design phase—not added later with stairs, platforms, and walkways that complicate the system and increase costs.

The layout is designed once, but its impact is experienced every day

An effective layout is not the result of compromises between existing constraints—it is a strategic choice that impacts the efficiency, safety, and scalability of a packaging line for years.

Design mistakes come at a cost every single day: downtime, waste, operational difficulties, and complex maintenance. And in many cases, these are avoidable errors—preventable with a broader perspective and collaboration with experts who understand the production dynamics of the food industry. At M.H. Material Handling we support our clients from the earliest layout design stages, combining conveyor system supply with consultancy that starts from flow analysis and extends to space optimization. If you are designing a new line or looking to improve an existing one, get in touch with us: we can assess the most effective solutions for your plant together.

Today’s food packaging lines are increasingly fast, automated, and high-performing. Individual machines can reach speeds and accuracy levels that were unthinkable just a few years ago.

And yet, in many plants, higher performance does not translate into a real improvement in overall line efficiency.

The reason is simple: a packaging line is not the sum of its machines, but a dynamic system where each station directly affects the others.

It is precisely within this delicate balance that the most common issues arise: unplanned downtime, micro-stoppages, and cascading slowdowns.

In this context, accumulation systems are no longer just an accessory—they are a key element that can truly make the difference in packaging line performance.

The accumulation system: the “lung” of the line

A useful way to understand the role of accumulation is to think of it as the “lung” of the packaging line—this is exactly how we at M.H. Material Handling define it.

An accumulation system is designed to “give breathing space” to the line, absorbing speed variations and temporary stoppages while maintaining a continuous product flow.

When a downstream machine slows down or stops (for example, during a reel change or adjustment), the accumulation system buffers the excess product, preventing upstream machines from stopping.

When the line restarts, the accumulated product is released in a controlled way, allowing partial recovery of production without stressing the system.

A simple principle, yet with a significant impact on overall line productivity.

The problems accumulation systems solve

In many packaging lines, certain inefficiencies are often accepted as unavoidable. In reality, they are frequently the result of missing or improperly sized accumulation.

1. Reel changes and line stoppages

Every film or packaging material change requires a machine stop. Without an accumulation system, this stop propagates across the entire line, halting even the sections that could otherwise keep running.

2. Different machine speeds

It is rare for all stations in a line to operate at the same speed.

Performance differences generate continuous micro-stoppages that negatively impact the entire process. Even small variations create instability, increasing component wear and reducing process predictability.

This is exactly where accumulation systems come into play.

Why accumulation is even more strategic today

While accumulation used to be considered optional, it has now become a strategic design choice. This is due to several factors:

• higher line speeds
• greater product variability (formats and packaging types)
• limited available space (especially in existing plants and especially in Italy)
• increasing pressure on overall system efficiency.

In this scenario, accumulation becomes a balancing tool, enabling smoother and more predictable product flow.

How to choose the right accumulation solution

One of the most common mistakes is to consider accumulation as a module to be added at the end of the line. In reality, its effectiveness depends on how it is designed and integrated into the system

Key factors to consider include:

• product type and its resistance to pressure
• line speed and differences between machines
• available footprint and vertical space
• required operating logic (FIFO or LIFO)
• working environment (e.g. maintenance and cleaning requirements)

Only by starting from these elements is it possible to define the most suitable accumulation solution, avoiding compromises that become costly over time.

Ultimately, designing accumulation means designing production continuity and line reliability. It cannot be treated as a standalone element: it must be developed based on line configuration, product flow, production targets, space constraints, and real operating conditions.

With M.H. Material Handling, this evaluation is carried out through a structured approach. Thanks to the M.H. Solution Scan, we analyze your packaging line in detail to identify critical areas and determine if, where, and how an accumulation system can improve operational continuity, reduce downtime impact, and increase real process efficiency.

Contact us to request the M.H. Solution Scan and discover how to make your packaging line more stable, efficient, and ready to handle daily production variability.

When it comes to “Hygienic Design”, many people immediately think of stainless-steel equipment, free of gaps and easy to wash down.
This is a correct image — but only a partial one.

The reality is that Hygienic Design does not start — and does not end — with the equipment.
It is a structured approach that takes shape much earlier, beginning with how the facility is conceived, built, and organized.

Only by considering the entire production ecosystem — from building structures and material flows to raw material handling and personnel procedures — can safety, efficiency, and sustainability be truly ensured.
Machines come later: their role is to protect and preserve what has been designed upstream, not to compensate for shortcomings at earlier stages.

The facility as the first link in the chain

Every Hygienic Design project therefore starts with the building layout.

Its location in relation to the external environment, the distance from potential sources of contamination, floor slopes designed to promote proper drainage, and thermal insulation all directly affect the ability to maintain hygienic conditions.

Selections of materials is equally critical: walls and surfaces must be easy to clean and durable over time

If a facility is not designed with these principles in mind from the outset, the cost will be significant: more washdowns, higher water and chemical consumption, and increased operating costs.

This is not a problem that can be solved with a high-quality machine alone, but with couscous design decisions made from the very beginning.

People, raw materials, and products: the flows that make the difference

The second level focuses on internal movements.

Ingredients, semi-finished products, and personnel must not share high-risk pathways. Any overlap increases the likelihood of cross-contamination.

For this reason, more advanced manufacturers implement a hygienic segregation of production areas, physically separating high-risk zones from low-risk ones and enforcing strict procedures: garment changes, controlled access points, and physical barriers. This approach, commonly referred to as hygienic zoning, is one of the most effective tools for reducing contamination risks within food processing facilities.

Machines are the protagonists, but procedures are the script

Only at this stage does the focus shift to machinery. Their role is not to “create hygiene,” but to preserve the hygienic conditions established upstream.

Features such as cleanable surfaces, open-frame designs, tool-free removable components, and food-grade certified materials are not optional details — they are essential requirements. A single poorly designed critical point is enough to turn a machine into a source of risk.

The cost of a mistake can be substantial: Commercial Food Sanitation estimates that a product recall caused by contamination costs, on average, €1.67 million in operational losses and reputational damage.

This is why Hygienic Design is not a technical detail, but a strategic investment.

We don’t sell machines — we design safety

At MH Material Handling, we believe that Hygienic Design is not something to be applied downstream, but a philosophy that must guide every decision throughout the entire process. This is why, although we specialize in the design of conveyor systems such as Saniflex, we do not limit ourselves to supplying a machine.

Our consulting approach always starts with a comprehensive analysis of the plant: we assess layout, material and personnel flows, sanitation practices, and production requirements in order to integrate the conveying solution into a context that is truly coherent, safe, and efficient.

Saniflex is not an off-the-shelf product, but a modular and customizable system, engineered to simplify cleaning, withstand aggressive detergents, and ensure operational continuity.

What truly makes it effective, however, is its ability to fit into a broader approach in which every design choice contributes to reducing risks, costs, and operational complexity.

Would you like to understand whether your line truly complies with Hygienic Design principles — and how Saniflex can enhance it to the fullest?

Contact us for a tailored consultation: together we will analyze your processes and identify the most effective solutions to protect product safety and strengthen your business competitiveness.

It already works well as it is… do we really need to change?

This is the question many plant managers ask themselves when they look at their packaging line.

If the machines are running, orders are being fulfilled, and production continues, why intervene in something that appears to be working?

The truth is that “working” does not always mean “working at its best.”

A small bottleneck, an unexpected buildup, one manual step too many: details that often go unnoticed, yet over time erode productivity, margins, and delivery reliability.

Today, the efficiency of a line is not determined by the power of individual machines, but by the ability to integrate and harmonize every component into a balanced, seamless flow.

Conveyors: the circulatory system of the line

Just as blood carries oxygen through the body, conveyors represent the circulatory system of a packaging line.

They are responsible for synchronizing machinery, absorbing fluctuations, and preventing bottlenecks.

If the flow is not continuous and well balanced, even the most advanced machine loses its effectiveness and the risk of downtime increases.

Yet these systems are often underestimated already at the design stage, resulting in inefficiencies that are difficult to correct later on.

Different solutions for different needs

At M.H. Material Handling, we know that no two lines are the same. That is why our solutions are designed to adapt to very different products, spaces, and processes.

Heliflex LIFO Spiral System

Ideal for large product accumulation with heights not exceeding 90 mm. This double-spiral system finds its optimal sizing with between 200 and 500 meters of available space.

BAT-Buffer Modular System

Modular and compact, it is perfect for handling different product types and plant layouts. It is versatile, easy to integrate into existing lines, and has relatively limited footprint requirements. Its ideal size ranges between 100 and 150 meters of available space.

5L FIFO Multilayer Belt

Developed specifically for the confectionery sector, it enables gentle multilane transport upstream of the packaging stations, reducing the risk of product damage.

These solutions are complemented by mergers, dividers, elevators, and intelligent handling units, all designed to ensure increasingly smooth and fully integrated material flows.

Efficiency is much more than speed

Being efficient today does not simply mean “running faster.”

It means designing ergonomic lines that are easy to clean, hygienic, and capable of making the most of the available space.

It means having systems that reduce downtime, optimize energy consumption, and ensure a long-term return on investment.

Our solutions, entirely made in Italy, reflect these values: they are reliable, customized, and built to last.

With nearly forty years of experience in the food and pharma sectors, at M.H. Material Handling we do more than supply individual components.

We always start with layout consulting, analyze material flows, and develop integrated conveying and buffering solutions that transform plants into efficient and competitive ecosystems.

Our goal is simple: to help companies increase productivity and stability while reducing complexity and hidden costs.

If your line “already works well,” ask yourself: is it really expressing its full potential?

A custom-designed conveying system can make the difference between a line that merely runs and one that grows.

Contact us for a personalized consultation and discover how to make your plant more fluid, safe, and efficient—without disruptive changes.