Boosting Efficiency for Packaging Machine Builders with Custom 3D Printing Solutions

The Industry Context

The food and beverage packaging world is changing fast. From growing sustainability expectations to shifting consumer habits and rising cost pressures, packaging machine builders are under more pressure than ever. They need to deliver machines that adapt quickly, perform reliably, and stay cost-efficient—all at once.

That’s where custom additive manufacturing (AM)—also known as industrial 3D printing—comes into play. This innovative technology is giving packaging machine builders a powerful way to stay ahead of industry demands, solve design challenges on the fly, and build better machines faster.

The Packaging Industry’s New Reality

Consumer habits are shifting rapidly. People are buying in bulk one day and looking for single-serve eco-friendly packaging the next. With growing calls for sustainable materials and faster product turnover, packaging lines need to be nimble and capable of quick changeovers.

This means machine builders are no longer just designing for volume—they’re designing for versatility.

Take Farason Corporation, for example. They were tasked with moving oddly shaped shampoo bottles on a high-speed production line. Off-the-shelf solutions were too heavy for their robot, which slowed down the line and hurt productivity. By turning to additive manufacturing, they created a custom, lightweight End-of-Arm Tooling (EOAT) that handled the job effortlessly—speeding up the line and improving performance.

Why Additive Manufacturing is a Game-Changer

Additive manufacturing builds parts layer by layer, which means you can create highly customized, complex components without expensive molds or long wait times.

For packaging machine builders, this is a huge win. Every new product may need slightly different grippers, guides, or mounts. With AM, you can design exactly what you need and print it quickly—without breaking the bank.

Farason didn’t just stop at grippers. They also used 3D printing to create a quick-change mount plate for a vacuum EOAT. Instead of relying on bulky machined parts, they printed a lighter and stronger version—one that could easily be modified in the future.

AM vs. Traditional Manufacturing: The Key Differences

Traditional manufacturing is great for large-scale production—but it comes with drawbacks: long lead times, high costs, and limited flexibility.

In contrast, additive manufacturing allows teams to:

• Design and iterate quickly
• Produce on-demand, in-house
• Cut down on material waste and weight
• Customize solutions for unique applications

At Suntory Products Limited, engineers implemented Markforged 3D printers in their Haruna plant to create high-strength parts in-house. This meant no waiting for outsourced components—and more control over quality and timelines. Whether it was jigs, covers, or tooling, everything could be customized and produced on the spot.

Solving Real-World Problems on the Line

Manufacturing teams today deal with a constant flood of SKUs, packaging refreshes, and new requirements. It’s not just about building a great machine—it’s about building one that can evolve.

With AM, it becomes possible to print changeover parts, grippers, and transport tools specifically for each new packaging spec—often in just a few hours. These custom components are lighter, more efficient, and designed with features like built-in vacuum channels or sensor mounts, eliminating the need for complex assemblies.

And because the parts are lighter, they work perfectly with smaller collaborative robots, enabling flexible deployment anywhere on the line.

One practical example: suction grippers used to move products into boxes at the final stage of packaging. By adjusting the design and grip distance for each product or box shape using 3D printing, teams can minimize robot load and maximize performance—without any external delays.

Addressing Major Pain Points in Packaging

Let’s face it: waiting weeks for a single custom part is frustrating—and expensive. Plus, coordinating with multiple vendors for small runs often creates more problems than it solves.

Additive manufacturing eliminates that headache. Companies like Farason have cut lead times from weeks to hours by printing EOAT components in-house. Not only did this slash costs, but it also ensured consistency across machines—so replacements fit perfectly every time.

What AM Brings to the Factory Floor

Here’s how additive manufacturing helps machine builders and manufacturers win:

• Better Machine Performance at Lower Cost: No more costly tooling or outsourcing. Just fast, functional, custom parts that keep your machines optimized. Farason’s EOATs, built using Markforged printers, are a perfect example—high-performance and low-cost.
• Faster Time to Market: Need to launch a new product quickly? With AM, your team can design and build the needed parts fast—no delays. Suntory used this approach to minimize product switchovers and keep production flowing.
• Cheaper, Quicker Spare Parts and Upgrades: 3D printing allows on-demand production of spares and upgrades, keeping customers happy and downtime low. Suntory produced nearly 900 parts in 8,000 hours, cutting maintenance delays and costs dramatically.

Where Additive Manufacturing Fits in Packaging

Here are some popular AM applications already making a difference in packaging machinery:

• End-of-Arm Tooling (EOAT): Lightweight, product-specific grippers for handling everything from bottles to bags.
• Cable & Hose Management: Custom clamps that hold up to complex robot movements without interference.
• Mounts & Brackets: Tailored components that integrate seamlessly into existing equipment.
• Changeover Parts: Quickly printed custom parts that speed up product transitions.
• Custom Transport Solutions: Lightweight containers and holders for unusual product shapes—designed, tested, and built in-house.

One standout use case: Farason designed and printed custom package containers for a snack brand. Their tailored solution beat traditional methods on performance and cost, helping them win the project.

Looking Ahead

The packaging industry isn’t slowing down—and neither can machine builders. Additive manufacturing gives them the flexibility, speed, and cost-efficiency needed to stay competitive in a fast-changing world.

From improving machine performance and cutting costs to delivering custom parts on-demand, AM is becoming an essential tool for the future of packaging. As more companies adopt this technology, we’re likely to see even more innovation, faster production, and smarter, more agile packaging systems everywhere.

At Chemtron, we empower packaging machine builders and manufacturers with cutting-edge additive manufacturing solutions—from prototyping to production-ready parts. With access to industrial 3D printers like Markforged and years of application expertise, we help you streamline operations, cut lead times, and future-proof your packaging lines.