Packaging Line Case Studies

Pail Filling Packaging Line

Packaging Line




After a negative experience with an OEM, the client looked to EPIC Systems to upgrade and integrate a pail filling machine and palletizer on a packaging line

Client: A Fortune 600 Company

Industry: Chemicals


  • Custom specified and modified palletizer
  • Semi-automatic, integrated control system
  • Custom infeed line, capper, crimper and lift assist
  • Complete and correct filler reprogramming
  • Accurate mass micro-flow meters


    • Came into the project halfway through it’s completion after another company failed to deliver results
    • Malfunctioning filler with programming issues
    • Tight budget and a project time-line that was already behind several weeks due to delays and ultimate abandonment by the OEM
    • Material that needed to be packaged according to mass


Front- End Engineering

EPIC first completed its front-end engineering approach to assure the most efficient process and accurate cost quotation. After reviewing the state of the current packaging/filling line with the client EPIC’s engineers completed a line evaluation and created an implementation plan that included the following elements:

    • Reprogramming of the original equipment in the pail filling line
    • Specifications for mass micro-flow meters for increased efficiency
    • An infeed line which included a capper, crimper and a lift assist at the end of the line
    • Control system integration to create a semi-automatic line

EPIC Systems recommended an efficient option for advanced line automation and machine vision inspection for QA checks.

EPIC’s Proven Solution

EPIC managed every aspect of the project including: assessment, packaging line re-design, mechanical and structural design, applied engineering and fabrication, controls engineering, installation, plant integration, FAT testing, and start-up and support. EPIC Systems reprogrammed the filler and also modified it with custom parts.

EPIC also fitted the pail filler with the specified mass micro-flow meters. This type of flow meter is not susceptible to changes in density or temperature of the fluid and performs more accurately than a volumetric meter for this application.

EPIC also set up an infeed line; capper, crimper and a lift assist at the end of the line. All of the equipment control systems were integrated together into the semi-automatic packaging line to meet the exact specifications set forth by the client.


    • Client has doubled their production level
    • Client has reduced the filling line from four operators, working two shifts, six days a week to two operators, working one shift, 6 days per month
    • EPIC helped the client to save significant amounts of money by working with the equipment already present


Packaging line integration firms see a project through the design, automation and start-up process. EPIC believes that we can help you “Do It Better” through:

    • Utilitzing Front-End Engineering to ensure that the proper steps are taken during project scope development
    •  By assisting clients in identifying their needs, pinpoint objectives and provide the most appropriate manufacturing equipment for the application
    • Keeping an open door client policy to promote innovation. We invite clients to visit EPIC to experiment with new processes, technologies and techniques that push the limits of traditional engineering.
    • Accountability to responsibly manage our clients’ projects from start-to-finish and beyond.
    • A transfer of knowledge (not just a basic training) for the systems and equipment we provide
    • Single point of direct contact during the entirety of the project
    • State-of-the-art shop which decreases down-time and increases the speed of project completion

Find a solution that is right for your company. Contact EPIC or learn more about packaging lines.


View Packaging Lines Case Studies…

Find case studies about different project applications EPIC has completed and specific unit operations within each project.


Click here to view our blog…

Our blog features topics on industry, engineering tips and company updates.

Press Release

View our latest press releases…

Stay up-to-date on what is happening at EPIC. You will find press releases on packaging line systems being delivered to clients, awards won by EPIC and new employees hired.

Free Newsletter

Stay up-to-date on current industry news and trends by subscribing to our packaging systems newsletter. Our newsletters are sent out semi-annually and cover interesting news, trends, industry topics as well as updates on EPIC Systems.

EPIC Packaging Systems
4134 Meramec Bottom Rd
St. Louis, MO 63129, US
(314) 845-0077

Send this to a friend