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We provide complete food and beverage packaging automation, from precise weighing and filling to case packing and palletizing. Our integrated systems deliver high throughput, reliable uptime, and easy changeovers for seamless end-to-end production.
We deliver complete bakery packaging automation, from flow wrapping, bagging, and product filling to case packing and palletizing. Our fully integrated systems ensure sanitary handling, high throughput, and smooth changeovers for seamless end-to-end bakery production.
We specialize in packaging automation for powders and granular products, delivering accurate weighing, dosing, and bagging from single-serve to bulk formats. Our integrated systems maintain freshness and ensure efficient, reliable end-to-end production.
We deliver complete frozen-product packaging automation designed to preserve cold temperatures and maintain product integrity. Our washdown-ready, sanitary systems are built for icy environments, ensuring reliable performance and seamless production from weighing and filling to end-of-line automation.
We provide flexible packaging automation for snack and confectionery products, designed to handle diverse shapes, sizes, and textures with ease. Our scalable, high-speed systems deliver efficient throughput in compact footprints, ensuring seamless production from primary packaging to end-of-line automation.
We provide sanitary, versatile packaging automation for pet food and pet care products, designed to handle unique shapes and applications. Our scalable systems support varied speeds and seamless production from primary packaging to end-of-line automation.
We deliver reliable packaging automation for household and cleaning products, engineered to safely handle liquids, powders, and chemical formulations. Our durable, high-quality systems ensure consistent performance and secure packaging from primary fill to end-of-line automation.
We provide packaging automation for personal care products, built to manage unique formulas and formats with precision. Our systems ensure rigorous packaging quality control and offer flexible machine speeds to support everything from small-batch runs to high-volume production.
We deliver precision packaging automation for health and medical products, engineered for safe, hygienic, and contamination-free handling. Our systems ensure accurate, secure packaging and meet the highest sanitation standards for trusted end-to-end production.
No matter the product, our versatile packaging systems are engineered to adapt and perform. You’re the experts in what you make — we’re the experts in packaging it. Together, we build long-term partnerships and reliable solutions that scale with your business and stand the test of time.
May 8, 2026
In food manufacturing, production challenges are often discussed in terms of labor, scheduling, supply chain delays, sanitation, communication, and yield loss. While these issues may not always begin with the machine itself, packaging equipment plays a major role in how well a facility responds when those challenges appear.
That is where spare parts become more than a maintenance item. They become a planning tool, a risk-reduction strategy, and a way to keep production moving when every hour of downtime matters.
For food processors and packaging teams, keeping the right spare parts on hand can help reduce emergency repairs, protect uptime, improve maintenance response, and create a stronger return on investment over time.
Unplanned downtime is rarely just one simple expense. It can impact labor, product waste, missed shipments, overtime, customer commitments, sanitation schedules, and the overall production plan.
When a packaging line stops because of one missing component, the cost is not only the part itself. The real cost includes the time spent diagnosing the issue, sourcing the replacement, waiting for shipment, rescheduling production, and restarting the line.
That is why the idea of “we’ll order it when it breaks” can quickly become an expensive strategy. Emergency parts, rushed shipping, delayed production, and lost efficiency often cost far more than maintaining a planned inventory of critical spare parts.
A smart spare parts program helps manufacturers shift from reaction to preparation.
Every operation has to manage costs carefully. No one wants to overstock shelves with parts that may not be needed for years. At the same time, carrying too little inventory can leave a production team exposed when a critical component fails.
The goal is balance.
A strong spare parts strategy helps identify which parts are critical, which parts are commonly replaced, and which components have longer lead times. This allows maintenance and operations teams to stock what matters most without overloading inventory.
Critical parts may include items such as belts, blades, sensors, sealing components, wear parts, contact parts, bearings, rollers, switches, electrical components, or machine-specific assemblies that are essential to keeping the line running.
The question is not simply, “How many parts should we keep?”The better question is, “Which missing parts would stop production if we did not have them?”
Labor shortages and skill gaps continue to affect food manufacturers across North America. New operators, temporary labor, and smaller maintenance teams can make troubleshooting more difficult, especially when a worn component begins affecting machine performance.
Having the right parts available helps reduce uncertainty.
Instead of losing valuable time identifying, ordering, and waiting for replacement parts, technicians can respond quickly and get the line back into operation. Spare parts do not replace training, but they do make it easier for teams to solve problems with confidence.
For facilities managing turnover or limited technical support, organized spare parts inventory can make maintenance response faster, cleaner, and more consistent.
High SKU variety is common in food manufacturing. Facilities may switch between package sizes, films, cartons, labels, formats, recipes, or product types throughout the week.
Every changeover matters.
When parts are worn, missing, or not ready, changeovers take longer. Operators may spend extra time adjusting the machine, troubleshooting seal quality, replacing small components, or trying to work around an issue that should have been handled before production began.
Keeping changeover-related and wear parts on hand helps reduce these delays. Fresh sealing components, knives, belts, guides, forming parts, rollers, and sensors can help teams move from one run to the next with fewer interruptions.
The more prepared the line is before a changeover begins, the less time is lost once production is ready to restart.
Most downtime events do not feel large at first. One belt wears out. One sensor fails. One blade dulls. One seal component begins causing inconsistent packages.
But one missing part can create a chain reaction.
A small issue can lead to stopped production, delayed shipments, overtime labor, increased waste, missed sanitation windows, and pressure on every department involved in the production schedule.
This is why spare parts planning is not just a maintenance concern. It is an operational risk strategy.
The line may be ready. The team may be ready. The product and packaging materials may be ready. But if one critical part is missing, the entire system can slow down or stop.
Food manufacturing has unique requirements that naturally interrupt production. Sanitation cycles, inspections, QA checks, documentation, and compliance steps are part of the process.
Reliable equipment helps those required interruptions go smoother.
Worn belts, damaged seals, cracked guards, loose fittings, or aging contact parts can create additional delays during inspection or startup. Having replacement parts on site helps maintenance teams address these issues before they become food safety concerns or production interruptions.
Spare parts also support preventative maintenance planning. Instead of waiting for a component to fail, teams can replace high-wear parts during scheduled downtime, sanitation windows, or planned service intervals.
That means fewer surprises during live production.
Not every issue shuts down the line immediately. Some problems quietly reduce performance over time.
Worn parts can contribute to poor seals, inconsistent cuts, misalignment, overfill, underfill, packaging defects, product waste, or rework. The machine may still be running, but the operation is losing efficiency with every imperfect package.
Replacing worn components at the right time helps protect package quality and production consistency.
In food manufacturing, small inconsistencies can become expensive quickly. A strong spare parts plan helps protect yield, reduce waste, and support a more stable finished package.
A spare parts strategy does not need to be complicated. It simply needs to be intentional.
Maintenance teams should review each machine and identify:
1. Which parts are critical to uptime?
2. Which parts wear most often?
3. Which parts have long lead times?
4. Which parts are needed for changeovers?
5. Which parts support sanitation and food safety?
6. Which parts are shared across multiple machines?
7. Which parts should be reordered once used?
This helps create a practical spare parts checklist for each line. It also helps avoid two common mistakes: stocking too much of what is rarely needed and not stocking enough of what can stop production.
Digital or organized manual tracking can also help teams monitor inventory levels, reorder points, usage history, and part numbers. The faster a team can find the right part, the faster they can recover.
For many maintenance teams, the challenge is not understanding the value of spare parts. It is justifying the investment internally.
The business case is simple: stocked critical parts reduce risk.
Leadership teams should consider the cost of one hour of downtime, one missed shipment, one emergency repair, one rushed shipment, or one extended production delay. In many cases, the cost of a small spare parts inventory is far less than the cost of waiting until something breaks.
Spare parts are not about expecting failure. They are about protecting production.
Spare parts are not just about fixing something after it breaks. They are about preparation, control, and confidence.
For food manufacturers managing labor challenges, changeovers, supply disruptions, sanitation requirements, planning gaps, and yield pressure, having the right parts on hand can make a measurable difference.
A well-planned spare parts inventory helps reduce avoidable downtime, support maintenance teams, protect product quality, and keep packaging lines ready for what comes next.
At PLAN IT Packaging, we believe spare parts are part of a stronger production strategy. Because when your line is prepared, your team can focus less on reacting to problems and more on keeping production moving.
For more than 150 years, Ganong Bros. has been part of Canada’s confectionery story. From iconic products like Chicken Bones and Pal-o-Mine to modern co-manufacturing partnerships across North America, the company has continued to evolve while staying rooted in quality, tradition, and innovation.
Today, we are proud to share that PLAN IT Packaging has been featured alongside Ganong Bros. in the April/May issue of Canadian Packaging magazine, highlighting a recent automation project designed to help support Ganong’s growing production demands.
As demand for Ganong’s confectionery and co-manufacturing services continued to grow, the company identified an opportunity to expand its packaging capacity while improving operational efficiency and redundancy.
To support this initiative, PLAN IT Packaging supplied and integrated:
The result was a packaging solution designed to improve throughput, flexibility, sanitation, and uptime while helping Ganong continue scaling production efficiently.
One of the key goals of the project was to avoid relying on a single high-output packaging system.
Instead, PLAN IT Packaging recommended four completely independent bagging lines. This approach provided Ganong with:
As highlighted in the article, this configuration allowed Ganong to exceed its original throughput expectations while maintaining continuous production capabilities if one line required servicing or maintenance.
“If one line does go down for any reason, at least you still have other lines up and running.”— Sal Choudhary, Sales Manager, PLAN IT Packaging
The installed Mars Rapid VFFS baggers were designed to support high-speed pouch production while maintaining sanitation and accessibility for operators.
Key system features included:
The ELITEWEIGH 24H multihead weighers also provided Ganong with increased weighing accuracy and versatility for handling a variety of candy and snack products.
According to the article, the new system helped Ganong achieve approximately 2.5 times the output of its previous packaging process.
One of the most important themes discussed throughout the feature was the role automation plays in supporting employees, not replacing them.
Ganong emphasized that automation investments are helping the company grow production while creating opportunities to upskill staff and improve engagement by reducing repetitive manual tasks.
This philosophy strongly aligns with PLAN IT Packaging’s approach to automation: implementing systems that help manufacturers improve efficiency, consistency, food safety, and operational reliability while empowering their teams for long-term success.
This project represents more than the installation of packaging equipment. It reflects the value of collaborative partnerships, thoughtful system design, and scalable automation strategies tailored to each manufacturer’s goals.
We are grateful to the Ganong Bros. team for the opportunity to support this exciting phase of growth and proud to see the project featured in Canadian Packaging magazine.
The full story dives deeper into Ganong’s incredible history, their approach to modernization, and the collaborative packaging automation project completed with PLAN IT Packaging.
Read the Full Canadian Packaging Article Here
PLAN IT Packaging delivers turnkey automation solutions for manufacturers across food, confectionery, snack, pet food, and consumer packaged goods industries.
From weighing and bagging to case packing, robotics, and palletizing, our systems are designed to help manufacturers scale with confidence.
Let's PLAN IT Together! Give us a call or tell us more about your packaging needs here.
April 24, 2026
PLAN IT Packaging is proud to announce the expansion of its Toronto/Mississauga operations with the acquisition of an additional 40,000 square feet of production space. This marks another major milestone in the company’s rapid growth across North America.
This expansion strengthens PLAN IT Packaging’s ability to support customers with greater speed, efficiency, and production capacity as demand for automation continues to rise. The new facility enhances internal workflows across assembly, fabrication, shipping, and overall project execution, enabling faster turnaround times and improved delivery performance. The added space also increases capacity for storing parts, supplies, and in‑stock systems, improving readiness for both new equipment builds and aftermarket support.
As client demand accelerates, this expansion ensures PLAN IT Packaging can continue meeting the evolving needs of manufacturers across multiple industries. PLAN IT Packaging specializes in weighing, bagging, flow wrapping, case packing, end‑of‑line robotics, and palletizing solutions, delivering fully integrated systems designed for modern, high‑performance production environments. The expanded facility will further support these core competencies by enabling larger builds, more parallel projects, and enhanced engineering collaboration.
The company now operates three facilities across North America:
Together, these locations reinforce PLAN IT Packaging’s long‑term investment in infrastructure, customer support, and scalable operations as it continues its trajectory toward becoming the premier North American leader in packaging automation and robotics.
The expansion also significantly grows PLAN IT Packaging’s Customer Experience Center, providing more room for equipment demonstrations, live product testing, and hands‑on evaluations of the latest packaging innovations. This environment allows customers to validate solutions in real time and collaborate directly with the PLAN IT team to optimize their production goals.
"Expanding our Toronto/Mississauga facility is another important step in our commitment to building a stronger, faster, and more capable organization for our clients,” said Jonathan Ballard, Vice President of Business Development. “This growth allows us to improve how we build, support, and demonstrate solutions while continuing to invest in the customer experience. Combined with our Tampa expansion and our dedicated R&D facility, it reflects our mission to become the premier North American supplier in packaging automation and robotics."
With this latest expansion, PLAN IT Packaging continues to invest in the people, processes, and facilities required to support the future of modern manufacturing.
May 11, 2026
For over 150 years, Ganong Bros. has been a recognized name in Canadian confectionery. As demand for branded and co-manufactured products continued to grow, the company needed a packaging solution that could increase throughput, improve flexibility, and support long-term operational reliability.
Ganong needed to expand packaging capacity without creating a single point of failure in production. The objective was to improve efficiency and scalability while minimizing downtime risks.
PLAN IT Packaging supplied and integrated four fully independent high-speed pouch packaging lines, including:
The systems were designed to support higher-speed production, simplified sanitation, faster changeovers, and improved operational redundancy.
The upgraded system helped Ganong significantly increase packaging output while maintaining flexibility across operations. By implementing four independent lines, production could continue even if one line required maintenance or servicing.
The project was also featured in the April/May issue of Canadian Packaging magazine as an example of scalable automation supporting manufacturing growth. Read full issue here.
February 11, 2026
Hardy Buoys Smoked Fish, a Canadian smoked fish producer supplying major grocery chains, faced significant operational challenges as demand for its products grew. Prior to automation, the company relied on a largely manual packaging process that required a large workforce making it difficult to scale output. Compounding this, the facility experienced persistent labor shortages, especially on the plant floor, and struggled to recruit workers despite high unemployment rates. As demand increased, Hardy Buoys was forced to reduce some orders, limiting its ability to expand customer relationships and meet market needs.
To address these hurdles, Hardy Buoys partnered with PLAN IT Packaging Systems to introduce automation into its packaging line. The core of the solution was an automated bagging line featuring:
By selecting a system capable of handling far more volume than existing production able to support up to 10,000 packages per day, Hardy Buoys positioned itself for both current and future growth.
The implementation involved installation of the RotoBagger line and training for plant operators. Although the COVID-19 pandemic delayed the initial setup by a few weeks, the line was successfully integrated into operations with support from Plan It Packaging’s technicians. Operators received two phases of training primary equipment familiarization and formal set-up procedures, enabling them to quickly operate and maintain the new system. Minor challenges such as incorrect bag sizing were resolved with Plan It’s responsive service and adjustments.
The transition to automated packaging delivered measurable benefits:
August 13, 2025
How The Carnivore Bar tripled its output and eliminated costly downtime with PLAN IT Packaging and FORT Capital
The Carnivore Bar, a company that makes shelf-stable, all-meat nutrition bars for outdoor adventurers and zero-carb purists, faced a packaging dilemma. The product needed airtight, high-integrity sealing—but the company’s initial equipment ultimately fell short of Carnivore’s high standards. After investing in a low-cost, imported flow wrapper, the team found themselves constantly troubleshooting breakdowns, wasting product, and manually sealing every bar by hand. “It was fine for launching, but it capped us. We couldn’t grow with it,” shared Carnivore founder Phillip Meese.
After two years of production delays, equipment band-aids, and escalating waste, Phillip knew it was time to scale—properly. “We needed a real machine. A professional-grade solution that would work every single day,” he said.But premium packaging machinery comes with a premium price tag, and Carnivore wasn’t ready for the cash flow hit. That’s when Phillip met the PLAN IT Packaging team—and through them, discovered FORT.
PLAN IT Packaging recommended a top-tier horizontal flow wrapper built for consistent performance and rugged durability. And FORT Capital stepped in to make it all attainable.Rather than applying for traditional financing and enduring a drawn-out process with unclear outcomes, FORT pre-approved Carnivore Bar quickly, structured flexible payments, and got the deal done without red tape.“FORT felt more like a partner than a lender,” said Phillip. “They understood our cash flow, our business stage, and they made it incredibly easy to say yes.”
With professional-grade packaging in place and financing that fit the business, The Carnivore Bar flipped the script. Production scaled, and wasted product vanished. Freed from the constant distractions of faulty machinery, Phillip’s team finally had the focus to drive real growth.
“Our old setup capped our growth. PLAN IT and FORT uncapped it,” Phillip said. “Now we can say yes to big orders, knowing we can deliver.”
About Carnivore Bar Carnivore Bar is on a mission to provide clean, shelf-stable nutrition for people who need it most—soldiers, adventurers, and everyday carnivores seeking real food without compromise. Designed for extreme durability and nutrient density, each bar is made with only meat, fat, and salt—no preservatives, no fillers. In a world where emergency rations often mean processed junk, Carnivore Bar exists to offer a better option: food that’s portable, unprocessed, and built to sustain. Learn more at carnivorebar.com.
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