In early 2022, a mid-sized food packaging company based in Coimbatore faced a common but frustrating problem: their existing pneumatic systems were slowing down production and increasing maintenance costs.
The owner of the company explained,
“We are running 3 packaging lines, but we constantly lose time due to inconsistent motion, compressor issues, and unplanned maintenance. We want a cleaner, more efficient setup.”
That conversation opened the door to a smart solution — electric actuators.
The Problem with Pneumatics
For years, the packaging industry relied heavily on pneumatic cylinders to perform repetitive motion tasks like:
- Pushing filled pouches
- Opening/closing sealing jaws
- Moving conveyors
- Adjusting guides or stoppers
While effective initially, these pneumatic systems came with headaches:
- Need for compressed air
- Frequent air leaks
- Noise and vibration
- Higher energy consumption
- Poor position accuracy
The company was spending lakhs every year just to keep the compressor running and maintain the valves and cylinders.
The Switch to Electric Actuators
We proposed a pilot project using electric linear actuators for the end-of-line pushing system, where the filled cartons were pushed onto a strapping conveyor.
Instead of a pneumatic pusher, we installed a compact electric actuator (24V DC, 300mm stroke, 1500N force) with a simple control panel. The result?
- No compressor needed
- Precise and repeatable stroke control
- Speed adjustable via potentiometer
- Instant reverse with minimal noise
- Zero air or oil leaks
The packaging line saw zero downtime due to actuator-related issues over the next 3 months.
Benefits They Experienced
After the trial, the company rolled out actuators across all 3 lines. Here’s what they gained:
Energy Savings
No need for air compressors — just plug-and-play 24V or 230V power.
Precise Motion
Actuators moved exactly to the set position every time — improving sealing accuracy.
Clean Operation
Perfect for food packaging – no risk of air or oil contamination.
Easy Maintenance
No valves, no hoses, no filters — just clean electrical motion.
Noise Reduction
Operators noticed the difference immediately — the entire line ran quieter.
Ideal Areas to Use Electric Actuators in Packaging Machines
- Carton pushers
- Bag lifters
- Guide rail positioning
- Flap closers
- Slicing or cutting arms
- Film tensioners
- Tray movers
Whether it’s vertical form-fill-seal machines or horizontal packaging systems — electric actuators can replace pneumatics in almost every motion task.
Final Thoughts
Electric actuators are not just a replacement — they’re an upgrade. For companies looking to improve speed, precision, and cleanliness in packaging, they are a future-ready solution.
As the Coimbatore factory manager later told us:
“We didn’t just remove compressors — we removed daily tension.”
If your packaging line is stuck in air-powered chaos, it’s time to switch to a smarter, cleaner electric drive.