Packaging Equipment Daily Maintenance Checklist: 3 Key Inspections to Reduce Downtime

Alyssa/October 7,2025

Unplanned downtime costs packaging operations an average of $3,200 per hour, according to the Packaging Machinery Manufacturers Institute (PMMI). For businesses aiming to boost productivity and cut losses, a simple daily maintenance routine focusing on 3 critical areas can reduce fault-related downtime by up to 45%. Below is a actionable checklist, with insights tailored to equipment like Hualian Packaging’s solutions.

1. Lubrication Systems: The “Lifeblood” Check

Insufficient or contaminated lubrication causes 30% of mechanical failures. Every morning, verify two key points:

Oil Level & Quality: For Hualian’s gearboxes and conveyor chains, check the sight glass—oil should sit between the “MIN” and “MAX” marks. If it appears cloudy or has metal shavings, replace it immediately (use Hualian-recommended ISO VG 46 lubricant for optimal performance).

Lubrication Points: Ensure auto-lubricators (standard on Hualian’s high-speed models) are functioning—clogged nozzles can lead to chain breakages, resulting in 8+ hours of downtime.

2. Electrical Connections: Prevent Hidden Risks

Loose or corroded wires are a top cause of sudden shutdowns. Focus on:

Terminal Blocks & Sensors: Inspect connections on Hualian’s control panels and photoelectric sensors (used for film alignment). Tighten any loose screws with a torque wrench (set to 2.5 N·m) to avoid arcing, which can damage circuit boards.

Cable Insulation: Check for cracks or fraying on power cables—especially near moving parts. Hualian’s equipment uses oil-resistant PVC cables, but daily checks still prevent costly electrical repairs.

3. Mechanical Wear: Catch Issues Early

Worn parts often lead to gradual performance drops before full failure. Prioritize:

Sealing Bars & Rollers: For Hualian’s heat-sealing machines, check if sealing bars have scratches (use a feeler gauge to test flatness). Worn rollers (used for film feeding) should be replaced when surface roughness exceeds 0.8 μm—delays here cause film jams, wasting 50+ meters of material per day.

Safety Guards: Ensure guards on conveyors and cutting mechanisms are securely fastened. Missing or loose guards trigger safety interlocks, shutting down equipment instantly—daily checks keep operations running smoothly.

By spending 15 minutes daily on these 3 inspections, businesses using Hualian Packaging equipment have reported a 38% reduction in unplanned downtime, saving an average of $12,000 per month. Consistency is key—integrate this checklist into shift handovers to avoid gaps.