How Automatic Packaging Machines Handle Diverse Product SKUs in FMCG
In the FMCG industry, product variety can be a strategic advantage, but it can also be a logistical nightmare: one brand may launch 20 different product SKUs, each with its own shape, size, and package type, and expect them all to go through the same production line.
So here’s the real question: How do you keep up with that level of complexity without losing speed, accuracy, or your mind?
The answer lies in how modern automatic packaging machines are built—not just to handle a product, but to handle change.
Let’s break it down.
What Is SKU in FMCG?
SKU (Stock Keeping Unit) refers to a unique identifier for each distinct product a business sells. For FMCG companies, SKUs include different flavors, sizes, bundles, or kinds of packaging of the same product.
The wider your portfolio, the more SKUs you have to manage and the more your packaging line needs to change.
Why SKU Diversity Creates Bottlenecks
It’s not producing the product that is the challenge; it’s packaging the product efficiently.
Here is what happens when SKU diversity is high:
- Changeovers happen frequently
- Error rates increase
- Downtime is increased by manual changeovers
- Greater risk of mismatched packaging
In a high-speed environment like FMCG, even a few extra minutes per changeover translates into thousands of lost units per shift.
Automatic Packaging Machines Built for SKU Agility
Modern automated packaging machines are no longer rigid systems locked into a single spec. The latest ones are designed for SKU flexibility, which means they can switch between products quickly with no downtime.
Here’s how they do it:
1. Recipe-Based Controls
Operators can switch between products by using pre-programmed “recipes” for every SKU, which incorporate bag size, box type, filling volume, sealing temperature, and label placement. Changeovers are just a push of a button.
2. Servo-Driven Adjustability
With servo motors, adjustments can be made virtually without limits and in real time. No need for manual settings to shift guide rails or calibrate sealing jaws because automated systems recalibrate for each SKU by themselves.
3. Smart Sensors and Vision Systems
These detect product size, position, and orientation, and ensure proper set-up, placement, and sealing even as products change.
4. Modular Design
Some systems are modular, meaning certain components (e.g., carton erector, filler, sealer, etc.) can be interchanged or adjusted relatively quickly based on individual SKU, without replacing the entire line.
Real-World Example: Alligator’s Case Packer for SKU-Diverse FMCG Packaging
Alligator Automations’ Case Packer is a great example of automation that can excel in SKU-heavy situations.
What makes it perfect for high-SKU FMCG lines:
- Handles multiple formats: It is built for all kinds of shapes and sizes.
- Fast SKU changeovers: The Case Packer uses programmable logic, smart sensors, and minimal manual intervention to switch from one SKU to another.
- High-speed throughput: It can keep up with the speed of modern filling lines without becoming a bottleneck.
- Organized case output: For retail-ready or shelf-ready formats, it ensures products are tightly packed, aligned, and protected
What Kind of FMCG Operations Benefit Most?
Multi-SKU automation generates the most value in operations that must frequently change packaging lines, whether that is due to pack count, bundle format, seasonal offers, or ever-changing marketing promotions. It is especially valuable in environments where downtime for manual changeovers directly impacts output and consistency in high-speed throughput.
If your packaging team juggles shifting order volumes, diverse carton sizes, or frequent reconfiguration of outer packs, secondary automation built to handle SKU complexity is not just a nice-to-have; it’s essential.
Automation That Works Across Your Entire Packing Line?
Managing SKU diversity doesn’t have to mean more downtime or bigger teams. An automatic packaging machine enables your line to manage complexity at scale.
One product, such as Alligator’s Case Packer, makes this possible, offering features built for diverse FMCG applications. But that is just part of the solution.
Alligator Automations offers a complete secondary packaging line: from case packers and carton sealers, to shrink wrapping systems, palletizers, and truck loading solutions. Each system works together, turning packed units into palletized loads ready for dispatch, without interruptions or manual handovers.
Ready to simplify your SKU? Let’s talk about building a packaging line that’s built for you. Contact us to explore the right solution for your line.
FAQs
What does SKU mean in the FMCG industry?
A Stock Keeping Unit (SKU) is a unique identifier used to track each specific product variant in inventory and production.Why is SKU diversity a challenge for FMCG manufacturers?
Because it demands frequent line changeovers, precise packaging adjustments, and error-proof flexibility—all without slowing production.How do automatic machines manage multiple SKUs efficiently?
By using programmable controls, servo-driven components, and smart sensing tech that adjusts packaging settings automatically for each SKU.What types of FMCG products benefit from multi-SKU automation?
Snacks, personal care items, detergents, and beverages with variant sizes or combo packs gain the most from automated flexibility.
