How to reduce downtime
Simple considerations can cut down line changeover time and increase efficiency., April 10, 2012
by Jim Stahlman, senior packaging manager, POWER Engineers
POWER Engineers

One of the biggest battles most companies face when dealing with production line changeovers from one product to another is the amount of lost production time that can result when getting the line operating efficiently after the changeover. Reducing changeover times can help get the line running at your target efficiencies.


Guiderails that adjust using a bolt and nut configuration, even if they are marked, can cause a lot of issues.

In the image above, red indicates guiderails set for smaller product and green indicates adjustment for larger product. This illustrates a guiderail adjustment on a straight transfer versus a slanted transfer, which allows for straight guiderails which are easier to adjust for changeovers.

Machine changeover

When buying new machines or units, operations pay close attention to changeover between products.

Product Considerations

Companies should always look for ways to standardize as many aspects of the product formats as possible.

Many of the aforementioned considerations come from practical hands-on experience. It is always better to involve your equipment manufacturers, engineering consultants and manufacturing team to review historical challenges, identify options and then employ modifications and initiatives that will streamline the process and minimize downtime.

This story is sponsored by POWER Engineers, which has one of the most comprehensive teams of engineers and specialists serving the baking and snack industry. As an extension of its clients' engineering teams, the company provides program management, integrated solutions and full facility design for the baking and snack industry. Learn more at