How Excelis Engineers are Integrating Packaging Lines
Building More Than Machines: Engineering Collaboration
Designing cost-effective, modular, and scalable packing solutions.
At Excelis, we’re not just connecting financial or operational systems, as often happens after companies merge. We’re working to integrate engineering, ideas, and technologies — a much more complex, but ultimately more rewarding, endeavor.
Malay Desai, our Director of Innovation at Excelis Automation, has taken on a challenge that goes beyond engineering individual machines. Malay explains, “This is especially important as we prepare for the upcoming Pack Expo trade show in Las Vegas this September/October, where we’ll showcase the first integrated line designed and built collaboratively across Excelis companies.”
Why This Challenge Matters
Historically, engineering teams within our family of companies have operated out of separate facilities, often tackling projects independently. Bringing these groups together means uniting different processes, design philosophies, and long-standing ways of working. It requires a cultural shift as much as a technical one.
Project management and open communication are at the heart of this transformation. Malay is spearheading efforts to ensure that engineers across all companies communicate regularly, align on shared goals, and leverage each other’s strengths. This is just the beginning — but it’s already delivering results.
Designing the Next Generation of Modular Machines
For our new capping and filling solutions, the journey began with market analysis, industry benchmarking, and conversations with customers to truly understand evolving needs. From there, we focused on three core design principles:
Scalability — so our solutions grow with customers’ production needs
Modularization — to enable faster customization and easier service
Cost-effectiveness — balancing performance with a strong ROI
As Malay puts it, “We’re putting in the engineering time upfront to make our new machines more modular. While engineering new solutions will never completely go away, this approach makes it faster and simpler for our customers.”
For example, our upcoming SureKap pump and trigger sprayer capping machine is being designed to start with up to 25 applications per minute, but built to easily scale up — without a complete redesign. This concept extends to integrated systems where you might see one, two, or three capping head machines alongside single or dual-head fillers with indexing, all working seamlessly together.
Looking Ahead
We’re thrilled to unveil these innovations at Pack Expo this fall, and even more excited about what’s in store with other new products for 2026. It’s inspiring to see engineering teams from across Excelis companies not just working side by side, but engineering together.
This is only the start. Stay tuned for more updates on how we’re reshaping what’s possible in packaging automation.
