Three Keys to Bring Equipment Online Rapidly & Efficiently

PMMI white paper presents a three-phase framework for building packaging line readiness, providing a roadmap to smarter, smoother startups.

Concept Picture

One enduring challenge in the packaging and processing industry, albeit one that has evolved somewhat with the introduction of sustainability considerations, is rapidly and efficiently bringing equipment online while also considering long-term sustainability.

PMMI’s new white paper, 2025 Performance Optimization: Insights for Packaging Line Readiness,” tackles this very topic, distilling the 2025 Top to Top Summit’s collaborative insights into a three-phase roadmap designed to help OEMs and CPGs align on startup success. These phases—Vertical Startups, Operator Training, and IT-OT Integration—form a cohesive strategy that goes beyond equipment performance and into the heart of operational readiness. The report underscores a simple truth: packaging performance hinges not just on machinery, but on people, processes, and communication.

Avoiding the post-startup dip

Once seen as aspirational, vertical startups—defined as the rapid and efficient transition from installation to full production—are now viewed as achievable and repeatable goals.

The white paper emphasizes that post-startup performance dips often result from insufficient training, a lack of planning, and misaligned expectations between OEMs and end users. The participants at Top to Top agreed that the antidote is early collaboration, starting as far back as the Request for Proposal (RFP) stage. This includes defining roles and responsibilities early (cited by 68% of respondents), identifying key success metrics for FAT and SAT, and clarifying what constitutes a “successful startup.”

On the OEM side, intuitive human-machine interfaces (HMIs) emerged as the most impactful factor in avoiding the dip, with 66% of OEMs citing the value of fault descriptions that point directly to root causes and suggest corrective actions. Providing spare parts lists, preventative maintenance plans, and training documentation before machine shipment also ranked high.

The report stresses that a successful vertical startup is not just about speed—it’s about sustaining momentum. OEMs and CPGs who invest in early communication, proactive risk management, and well-prepared teams see less downtime and better OEE outcomes post-installation.

Rethinking operator training

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