In contract packaging, a stopped line isn’t just your problem.

It's your client's problem too.

Machine Analyser® connects directly to your PLC – fault data, error codes and drive history instantly. No sensors, no IT project. Real breakdown data the moment your line stops – keeping your lines running and your client commitments intact.

Packaging downtime isn’t just a machine problem.

It’s a diagnosis, knowledge and parts problem.

When a packaging line stops, four things need to happen – diagnose, understand, fix and learn. In contract packaging, every hour costs you twice – lost production and a client commitment you can’t meet. Machine Analyser® is built for all four. Not just the prediction bit.

Diagnose fast - with the right data

When a packaging line goes down, Machine Analyser® surfaces the exact fault, axis, error code and preceding events from your PLC immediately. No log searching, no guesswork - your engineer has everything they need to diagnose the problem in minutes, not hours. Every minute counts when a client's product is on the line.

Understand the problem and fix it

Knowing the fault code is only half the battle. Machine Analyser® gives your engineers the full context - drive history, error patterns and preceding events - so they understand what caused it. With a full asset inventory including parts and firmware versions, your team resolves it fast - minimising the impact on your client's schedule.

Log it, learn from it, prevent the next one

Every breakdown is logged automatically. Machine Analyser® tracks patterns across incidents so your team can spot recurring faults - particularly on ageing PacDrive M equipment - and take action before the same problem stops the line again.

Built for the engineers keeping packaging lines running.
React, resolve and prevent – all from your PLC.

Connected directly to your PLC — no sensors, no lengthy IT project. Whether you run a single line or a multi-client operation, everything your engineers, managers and stores teams need in one platform.

Phase 1 — Breakdown
React to Breakdowns

When a packaging line stops, Machine Analyser® pulls the fault, axis, error code and preceding events from your PLC instantly. No log searching – your engineer has the full picture before they’ve even reached the machine, minimising the impact on your client’s production schedule.

Phase 2 — Prevention
Monitor Performance

Machine Analyser® tracks current draw, error trends and axis behaviour across your packaging lines 24/7 – through format changeovers, product switches and high-speed runs. Spot what’s developing on your filling, forming and wrapping lines before it becomes a stop.

Phase 3 — Planning
Plan Smarter 

Usage data, wear trends and a full asset inventory – parts and firmware versions included. Especially valuable for ageing PacDrive M systems where parts availability is tightening. Plan maintenance windows around actual condition, not a fixed calendar.

In packaging, downtime doesn’t just cost you.
It costs your clients too.

Industry research and the reality we see every day on the packaging factory floor.

£40K

The REAL cost of one hour of unplanned downtime on a packaging line

81 min

Average incident duration – up from 49 minutes five years ago

12 hrs

Time that can be lost in a single incident when cleanup is required

9/10

Manufacturers want condition monitoring but most still don’t have it

From Installation to Intelligence in 3 Simple Steps.

No rip-and-replace. No lengthy IT project. No sensors to install. Works with existing PacDrive M and PacDrive 3 systems - no upgrade required.

Connect

Plug directly into your PLC - no sensors, no hardware, no disruption. Works with ELAU PacDrive and legacy systems instantly.

Monitor

Cloud or offline - no IT sign-off. Continuous PLC data tracking. Learns patterns and flags anomalies with 24/7 coverage.

Act

Turn insights into action. Get instant alerts, predictive warnings, and plain-language tips for faster, smarter planning.

Built for the realities of packaging manufacturing.

Packaging lines face pressures unique to the sector – high-speed operation, frequent format changes and the added weight of client commitments. Machine Analyser® is designed for all of it.

  • High-Speed Filling & Wrapping Lines

    Real-time monitoring on your fastest, most critical lines

    Track current draw and axis behaviour on filling, forming and wrapping lines running at high speeds - where small issues escalate fast. Machine Analyser® surfaces early warning signs before they become stops, and gives your engineer the full fault context the moment one does. On a high-speed line, every minute of diagnosis time costs you throughput.

  • Multi-Format Changeovers

    Consistent reliability across every format and product switch

    Format changeovers are one of the biggest stress points for packaging equipment - motors, drives and axes pushed through repeated configuration changes. Machine Analyser® tracks machine condition across every changeover so your team can see what's being stressed and catch issues before they stop the next run.

  • Client Commitments & Supply Chain Pressure

    Protect your client relationships as well as your throughput

    TIn contract packaging, your downtime is your client's problem. A missed delivery window affects their supply chain, their retail commitments and ultimately their trust in you. Machine Analyser® gives your team the tools to respond fast, resolve quickly and reduce the frequency of unplanned stops - protecting both your operation and your client relationships.

  • Legacy PacDrive M Equipment

    Extend the life of ageing equipment with better data

    Many packaging lines run on PacDrive M systems that have been in service for years. As component availability tightens, knowing the condition of every drive, motor and controller becomes critical. Machine Analyser® tracks wear trends and flags deteriorating components so you can plan replacements before they fail - and make the most of every part you have.

  • Tight Margins & Cost Control

    Reduce emergency costs through smarter maintenance

    Contract packaging runs on thin margins - emergency callouts, unplanned repairs and expedited parts orders eat into profitability fast. Machine Analyser® gives your maintenance team the data to plan ahead, reduce reactive repairs and keep maintenance costs predictable. Less firefighting, more control.

Ready to keep your packaging lines running and your client commitments intact?

No sensors. No lengthy IT project.
No rip-and-replace.
FULLY OFFLINE AVAILABLE. Connect to your PLC today and get your first insights before the end of the day.

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