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Automation Applications

Integrated Packaging Systems for Pail Fill Line

After a negative experience with an OEM, the client looked to EPIC  to upgrade their integrated packaging systems which included  pail filling machines and a palletizer

Client: A Fortune 600 Company

Industry: Chemicals

integrated-packaging-systemsKEY ENGINEERING FEATURES:

  • Custom specified and modified palletizer
  • Semi-automatic, integrated control system
  • Custom infeed line, capper, crimper and lift assist
  • Complete and correct filler reprogramming
  • Accurate mass micro-flow meters


    • Came into the project halfway through it’s completion after another company failed to deliver results
    • Malfunctioning filler with programming issues
    • Tight budget and a project time-line that was already behind several weeks due to delays and ultimate abandonment by the OEM
    • Material that needed to be packaged according to mass


Front- End Engineering

EPIC first completed its front-end engineering approach to assure the most efficient process and accurate cost quotation. After reviewing the state of the current packaging/filling line with the client EPIC’s engineers completed a line evaluation and created an implementation plan that included the following elements:

    • Reprogramming of the original equipment in the pail filling line
    • Specifications for mass micro-flow meters for increased efficiency
    • An infeed line which included a capper, crimper and a lift assist at the end of the line
    • Control system integration to create a semi-automatic line

EPIC Systems recommended an efficient option for advanced line automation and machine vision inspection for QA checks.

EPIC’s Proven Solution

packaging-systems-integratedEPIC managed every aspect of the project including: assessment, packaging line re-design, mechanical and structural design, applied engineering and fabrication, controls engineering, installation, plant integration, FAT testing, and start-up and support. EPIC Systems reprogrammed the filler and also modified it with custom parts.

EPIC also fitted the pail filler with the specified mass micro-flow meters. This type of flow meter is not susceptible to changes in density or temperature of the fluid and performs more accurately than a volumetric meter for this application.

EPIC also set up an infeed line; capper, crimper and a lift assist at the end of the line. All of the equipment control systems were integrated together into the semi-automatic packaging line to meet the exact specifications set forth by the client.


    • Client has doubled their production level
    • Client has reduced the filling line from four operators, working two shifts, six days a week to two operators, working one shift, 6 days per month
    • EPIC helped the client to save significant amounts of money by working with the equipment already present



Packaging line integration firms see a project through the design, automation and start-up process. EPIC believes that we can help you “Do It Better” through:

    • Utilitzing Front-End Engineering to ensure that the proper steps are taken during project scope development
    •  By assisting clients in identifying their needs, pinpoint objectives and provide the most appropriate manufacturing equipment for the application
    • Keeping an open door client policy to promote innovation. We invite clients to visit EPIC to experiment with new processes, technologies and techniques that push the limits of traditional engineering.
    • Accountability to responsibly manage our clients’ projects from start-to-finish and beyond.
    • A transfer of knowledge (not just a basic training) for the systems and equipment we provide
    • Single point of direct contact during the entirety of the project
    • State-of-the-art shop which decreases down-time and increases the speed of project completion

Find a solution that is right for your company, Contact EPIC.

Get Started

Are you ready to get started with your automation project? Contact an engineer today 314-254-9768 to discuss your application. At EPIC you will be put in direct contact with a project engineer who will help you get started...

EPIC Industrial Automation
4134 Meramec Bottom Rd
St. Louis, MO 63129, US