On the factory floor of a mid-sized FMCG company in Coimbatore, a packaging line buzzed along at full speed. Cartons slid across the conveyor belts, labels were being applied in perfect alignment, and flap-folding machines sealed the boxes with remarkable precision. What made this line different wasn’t visible to the naked eye — it was the shift that had happened behind the scenes.
Just a few months earlier, the same line was running with pneumatic cylinders. Maintenance was constant. Leaks, noise, jerky movements, and inconsistent sealing were part of everyday problems. The engineering head, frustrated with the rising downtime and unpredictable air pressure issues, decided it was time for a change.
Enter compact electric linear actuators.
They started by replacing a few pneumatic cylinders in critical areas — the label applicator, the box flap sealer, and the product pusher. The difference was immediate. The electric actuators operated quietly, moving with smooth, controlled motion. They were accurate to the millimeter. No more constant compressor running. No more hiss of leaking air.
The real magic, though, was in the control.
Since the electric actuators were programmable, the engineers could now fine-tune the speed and stroke length directly through the PLC. When the team wanted to change the carton size, they didn’t have to mechanically adjust the guides or replace parts. A quick program update and the actuator adjusted automatically — a process that earlier took 15–20 minutes now took less than one.
Over time, they converted the entire line. Energy bills dropped. Uptime improved. Maintenance calls reduced drastically. The operators who once struggled with noisy, leaky air lines were now working beside clean, whisper-quiet machines.
And the most interesting part? These actuators weren’t imported. They were indigenised — designed and manufactured in India.
This shift to locally built actuators not only reduced lead time for spares and support, but also made the transition cost-effective. The manufacturing team had more control over design customisations, stroke lengths, and mounting brackets. What started as a simple automation upgrade soon became a symbol of smart engineering and self-reliance.
Today, that factory is considered a benchmark within their group of companies. Other divisions have followed suit, inspired by the success of this packaging line. The management proudly showcases the setup to visitors, and the story of their electric actuator journey is often told at industry conferences.
In the world of automation, change doesn’t always have to be disruptive. Sometimes, it’s about replacing what doesn’t work with something that works better, smarter, and cleaner. That’s the story of compact electric actuators in packaging lines — a quiet revolution, one push at a time.