Expanding or upgrading a packaging line can be a complex process, especially when integrating new machinery into an existing setup. At C.E.King Limited, we understand that businesses need seamless, efficient, and cost-effective solutions that don’t disrupt production.

Whether you're adding a tablet counting machine, liquid filler, or bottle capping system, this guide outlines how to successfully integrate C.E.King Limited’s packaging machinery into your existing production line.

Step 1: Assess Your Current Production Line

Before adding new equipment, it’s important to evaluate your existing production setup to ensure compatibility. Key factors to consider include:

• Production Speed & Throughput – Will the new machine match or improve your current production rate?
• Space & Layout – Does your facility have sufficient space for the new equipment?
• Packaging Format & Compatibility – Are your current bottle sizes, caps, and packaging materials compatible with the new system?
• Regulatory Compliance – Ensure that the new equipment meets industry standards for pharmaceuticals, food, and personal care packaging.

Tip: Conducting a site audit with our engineering team can help identify potential bottlenecks and efficiency improvements before installation.

Step 2: Select the Right Machinery for Your Needs

C.E.King Limited offers a range of tablet counting, liquid filling, and capping solutions that integrate with different production environments.

Choosing the Right Machine

• Tablet Counting Machines – Ideal for pharmaceuticals, nutraceuticals, healthcare, veterinary, confectionery, and other industries, ensuring accurate dosage with minimal waste.
• Liquid Filling Machines – Suitable for cosmetics, skincare, personal care, chemicals, and other similar products, offering precision filling for different viscosities.
• Bottle Capping Machines – Automate sealing with screw caps, ROPP caps, and push-fit closures, ensuring secure and tamper-proof packaging.

Tip: If your production involves multiple packaging formats, consider customising your machine settings for quick changeovers.

Step 3: Ensure Smooth Mechanical & Electrical Integration

Once the right machine is selected, the next step is to integrate it seamlessly into your production flow.

• Conveyor System Compatibility – Ensure the new machine aligns with existing conveyor speeds, bottle spacing, and direction of movement.
• Electrical & Control System Integration – Machines must be compatible with your facility’s power supply, PLC systems, and automation controls.
• Machine Positioning & Workflow Optimisation – Placing equipment strategically can reduce manual handling, improve efficiency, and prevent production slowdowns.

Tip: Modular and adjustable-height machines are easier to integrate, allowing for flexible positioning and expansion in the future.

Step 4: Testing & Calibration for Optimal Performance

After installation, thorough testing and calibration are essential to ensure the machinery operates efficiently within your existing setup.

• Dry Runs & Test Batches – Run test cycles to verify accuracy, speed, and overall functionality before full production begins.
• Adjusting Fill Levels, Speeds & Tolerances – Fine-tune settings based on your product viscosity, bottle size, and production targets.
• Error Detection & Troubleshooting – Identify potential issues early to prevent production stoppages.

Tip: Keep a record of initial machine settings during testing to make future adjustments easier.

Step 5: Training Your Team for Efficient Operation

Even the most advanced machinery requires proper training to maximise its potential. C.E.King Limited offers on-site and remote training for operators and maintenance staff, covering:

• Machine Operation & Safety Procedures – Ensuring staff can use the equipment correctly and efficiently.
• Basic Troubleshooting & Maintenance – Helping teams identify common issues and routine servicing needs.
• Quick Changeover & Setup Adjustments – Training on how to switch between different packaging formats without major downtime.

Tip: Well-trained staff reduce the risk of operational errors and machine downtime, improving overall productivity.

Step 6: Ongoing Support & Maintenance for Long-Term Efficiency

To ensure smooth operation over time, it’s important to keep machinery well-maintained.

• Routine Servicing & Preventative Maintenance – Regular servicing helps extend equipment lifespan and maintain efficiency.
• Technical Support & Spare Parts Availability – C.E.King Limited provides fast-response technical support and a stock of essential spare parts.
• Upgrades & Future Expansion – As your production needs grow, our team can advise on additional upgrades or modifications.

Tip: Scheduled maintenance reduces the risk of unexpected breakdowns, keeping production running without costly disruptions.

Why Choose C.E.King Limited for Your Packaging Machinery?

C.E.King Limited specializes in flexible and efficient packaging solutions for a wide range of industries, including pharmaceuticals, healthcare, veterinary, nutraceuticals, cosmetics, skincare, personal care, chemicals, food & beverage, and beyond.

✔ Seamless integration with existing production lines
✔ Customizable machinery for different packaging needs
✔ Full training and after-sales support
✔ Proven track record of delivering high-quality solutions worldwide

If you're looking to upgrade your packaging line with minimal disruption, our team is here to help.

Final Thoughts

Integrating new machinery into an existing production line doesn't have to be complicated. By carefully planning, testing thoroughly, and training your team, you can achieve a seamless transition with improved efficiency and output.

Contact us today or visit www.ceking.com to learn more about how we can support your packaging operations.