Polybag Sticker Pasting
Machine Redesign
Redesigning an existing size-specific sticker pasting machine at MAS Holdings into a flexible, reconfigurable system capable of handling multiple polybag sizes — eliminating frequent changeover downtime through adjustable guide rails, modular subassemblies, and SolidWorks parametric CAD.
Project Overview
The original sticker pasting machine at MAS Holdings was designed to handle only a single polybag size, requiring a dedicated machine for each product dimension. This caused frequent production changeovers, increased downtime, and higher operational complexity as product ranges expanded.
The redesign objective was to develop a flexible, reconfigurable mechanical system capable of handling multiple polybag sizes on a single machine without compromising alignment accuracy, throughput, or reliability. The approach focused on quick adjustability, repeatability, and ease of operation — ideally without requiring tools for size changeovers.
The full redesign was performed in SolidWorks using parametric modelling and assembly design, with interference detection and manufacturing feasibility checks throughout.
Machine Process Flow
Three sequential subassemblies handle the full sticker-pasting operation, each independently adjustable for different polybag sizes.
Design Approach
Four mechanical design principles guided the redesign strategy.
Adjustable Guiding System
- Sliding guide rails for variable polybag widths
- Lead screw / slot-based width adjustment
- Parallel alignment maintained across all sizes
- Prevents bag skewing during feeding
Sticker Application Alignment
- Redesigned applicator maintains position across sizes
- Accurate alignment relative to bag edges
- Adjustable mounts for fine-tuning sticker position
- Consistent placement validated via CAD assembly
Modular Design Concept
- Feeding, alignment, and dispensing as separate modules
- Each subassembly independently replaceable
- Easier maintenance and future upgrades
- Parametric CAD scaling for new bag dimensions
Ergonomics & Changeover Speed
- Tool-free manual adjustments where possible
- Reduced setup time between size changes
- Improved operator usability and reduced error
- Designed for factory floor constraints
CAD & Simulation
Full SolidWorks parametric workflow from concept to validated assembly.
Results & Impact
Key outcomes from the redesign at MAS Holdings.
Successfully enabled multi-size polybag handling on a single machine — eliminating the need for separate dedicated machines per product size.
Reduced downtime from size changeovers — adjustable guide system allows rapid re-configuration without tooling.
Improved operational efficiency and machine utilisation across product lines through a cost-effective retrofit rather than new machine investment.
Modular subassembly architecture enables future upgrades and easier maintenance — each of the three units can be independently serviced or replaced.