Across plastics and packaging plants, hidden losses quietly accumulate—driven by scrap, downtime, energy waste, and quality variability.
When equipment health isn’t visible in real time, small issues quietly escalate into costly downtime, leading to issues such as:
Injection molding, blow molding, and extrusion lines stop without early warnings
Tooling and mold wear detected too late
Microstoppages on packaging lines remain invisible
Unplanned downtime disrupts delivery commitments
.webp)
Variability in material preparation, feed, and changeover processes often goes unnoticed, leading to problems such as:
Excessive startup scrap during mold and SKU changeovers
Inconsistent material feed and drying conditions
Limited visibility into regrind vs virgin material usage
High resin and film wastage impacting margins
.webp)
Rising energy costs combined with limited consumption visibility expose manufacturers to margin erosion and reporting challenges, including:
High power draw from heaters, compressors, and chillers
No real-time visibility into energy per cycle or SKU
Idle utilities running during line stoppages
Rising Scope 1/2/3 reporting requirements
.webp)
Variations in molding and packaging conditions often go unnoticed until final inspection, resulting in problems such as:
Defects like warpage, short shots, flash, bubbles, and seal failures
Manual inspection unable to keep up with line speed
Limited traceability across cavities, molds, and batches
Rework and customer rejections impacting trust
.webp)
Disconnected data and manual processes make it difficult to maintain accurate sustainability records, manifesting as issues such as:
Manual tracking of waste, recycling, and emissions
Fragmented documentation for audits and certifications
Limited insight into recycled content usage
Difficulty meeting brand-owner sustainability targets
.webp)
Faclon delivers end-to-end visibility and intelligence across plastics processing and packaging operations
Deliver measurable performance gains by aligning production, energy, maintenance, quality, compliance, and IT through a unified digital foundation.

Faclon’s platform unifies machines, molds, utilities, quality systems, and enterprise applications into a single intelligence layer purpose-built for high-speed plastics and packaging operations.

