Success Story: A Simple Material Change Delivers 10× Performance in High-Speed Packaging
In high-speed packaging environments, even the smallest components can have an massive impact on performance, uptime, and operating cost. A leading manufacturer of gum blister packs learned this firsthand while running an extremely demanding pick-and-place application at 110 picks per minute.
The customer’s packaging line relied on vacuum-based gripping to handle lightweight blister packs at high acceleration rates. While the system met throughput requirements, it suffered from a persistent reliability issue: premature wear of the vacuum suction cups. The line was originally equipped with silicone suction cups, which were failing far earlier than expected due to the speed, cycle rate, and repetitive contact inherent in the application.
Frequent cup replacement led to rising component costs, increased maintenance labor, and unplanned downtime - directly impacting OEE, overall equipment effectiveness. Although the suction cups were relatively inexpensive components, the cumulative cost of replacements and lost production quickly became significant.
Finding the Right Solution
TSI partnered with the customer and Piab to evaluate the application in detail. Through testing and material analysis, it became clear that while silicone offered flexibility, it was not well suited for the long-term durability demands of this high-speed blister pack handling process. TSI coordinated testing with Piab and recommended a material change to Piab F20MF.40 TPU flat suction cups.
The results were immediate and measurable. The TPU cups delivered extended service life compared to the original silicone cups, while maintaining consistent grip and placement accuracy at full line speed. The improved wear resistance dramatically reduced replacement frequency and stabilized line performance.
The Takeaway
By making a simple change to a component costing under $10, the customer realized large savings through reduced consumable costs, lower maintenance labor, and minimized downtime. Just as importantly, the packaging line gained reliability and predictability - critical factors in high-volume consumer goods production.
This project highlights how targeted application knowledge, supplier collaboration, and material selection can unlock major operational gains. In high-speed packaging, sometimes the biggest improvements come not from complex redesigns—but from choosing the right material for the job.
