As an automated packaging system supplier who’s spent the last 12 years troubleshooting, installing, and maintaining equipment across 17 countries, I’ve lost count of how many times a client’s project has hit a delay because they skipped the basic storage step before their new system even arrived. I still remember a 2021 launch for a mid-sized snack manufacturer in Ohio: their warehouse team stacked uncrated robotic packaging arms directly against a leaky exterior loading bay wall, thinking “storage is just keeping boxes dry.” By the time our on-site crew arrived to install, the steel servo motor housings had developed 3mm of surface rust, the touchscreen’s waterproof seal was cracked from exposure to 40°F rain, and we had to order custom replacement parts that pushed their launch back six weeks. That incident wasn’t a manufacturing flaw—it was a storage mistake that could’ve been avoided with clear, specific guidelines tailored to automated packaging systems. Automated Packaging System
Automated packaging systems (APS) aren’t like manual workbenches or handheld tools. They’re integrated, precision machinery with delicate electronics, hydraulics, and actuators that rely on consistent conditions to function once powered on. Store them wrong, and even top-tier components from leading brands degrade before they ever run a single package. Let’s break down the non-negotiable storage conditions our team outlines for every client, split by pre-delivery, short-term, and long-term storage, plus the common pitfalls we see all the time.
First, pre-delivery storage is the window between when your system leaves our factory and when it’s delivered to your facility. Most APS are shipped in crates with climate controls integrated for long-haul transit, but many clients cut corners here—either leaving crates on truck beds for extra days, or storing them in unconditioned freight yards while waiting for final facility prep. From our testing, the sweet spot for pre-delivery storage is a conditioned, enclosed space, with a relative humidity (RH) between 40% and 60% and temperature held between 50°F and 80°F. RH over 65% is the biggest risk here: even sealed crates can develop internal condensation if the ambient RH spikes, which corrodes exposed wiring terminals and eats away at hydraulic line fittings. We’ve seen crates left in a Miami freight yard during hurricane season develop internal moisture buildup that required a full deep clean of the system’s control panel, adding $12,000 in unplanned costs to a $450,000 APS order. For outdoor storage, if you have no other option, cover crates with a breathable UV-stabilized tarp (not plastic—plastic traps moisture) and elevate them 6 inches off the ground with pallets to avoid ground water seepage.
Next, short-term storage is the period between delivery and installation, usually 2 to 8 weeks. This is where most in-house warehouse teams make their biggest errors. Unlike pre-delivery crated systems, once you’ve uncrated an APS to start site prep, you expose it directly to your facility’s environment. The key here is protecting two vulnerable areas: electrical components and moving parts. For electrical cabinets—home to programmable logic controllers (PLCs), touchscreens, and power drives—never leave their doors open for more than 30 minutes at a time. Dust is a silent enemy here: even a thin layer of dust on a PLC fan can cause overheating during operation, and if that dust gets damp, it creates a short circuit. We had a cosmetics client in France leave their APS control cabinet door open while they ran electrical wiring, and a small amount of face powder dust settled on the circuit board—costing them a week of production and $8,000 in repairs when the PLC fried on first startup. For moving parts like robotic arms, conveyor belts, and pneumatic cylinders, keep them protected from extreme temperature swings. If your facility’s loading dock drops to 32°F in winter and hits 95°F in summer, the lubricant in the cylinders can thicken or break down, leading to jerky, inaccurate movement. Our recommendation here: wrap exposed moving parts in heat-shrink plastic (designed for industrial equipment, not residential wrap) and lightly coat them with a food-grade, rust-inhibiting lubricant if the storage period will exceed 4 weeks—even if your facility is conditioned.
Long-term storage, defined as periods over 8 weeks before installation, requires a more rigorous setup. This is common for clients building new facilities or coordinating multiple equipment deliveries, so it’s a scenario we prepare for in every system’s user manual. For long-term storage, first move the entire APS into a dedicated, dry storage space—not a shared warehouse aisle. Ideally, this space should have consistent temperature (55°F to 75°F) and RH (45% to 55%), with no direct sunlight hitting any components. Sunlight isn’t just a glare issue for touchscreens: UV rays break down the plastic insulation on wiring and cause conveyor belt materials to crack over time. We once audited a storage facility for a pharmaceutical client in Germany, where their robotic packaging system was parked in a space with large south-facing windows; after 10 weeks, the 3mm thick belt on their blister packaging line had shrunk by 2mm, leading to misaligned packs that required full belt replacement.
Next, for long-term storage, you need to perform monthly checks, even if the system is covered. The most critical checks are: inspecting electrical seals for cracks or gaps (use a flashlight to look for condensation inside cabinets), testing the lubricant on moving parts for thickness (if it’s clumpy, reapply a thin layer), and verifying that any cranes or hoists used to move parts are functioning (you’d be surprised how often a small equipment failure during storage turns into a 24-hour delay when you’re ready to install). Another key step for long-term storage: disconnect all battery backups (used for PLCs and control panels) and store them separately in a cool, dry space. Batteries self-discharge over time, and leaving them connected for months can cause them to leak acid, which damages circuit boards. We learned this lesson the hard way in 2019, when a client in Canada left their battery backups connected for 12 weeks; the lithium-ion batteries leaked, corroding three circuit boards, and we had to source replacements from a supplier in Japan, pushing their installation back two months.
Now, let’s talk about the non-environmental storage factors that are just as important as temperature and humidity. First, orientation and positioning. Most APS are designed to be stored in their operational orientation—meaning robotic arms facing upward, conveyors level, no parts stacked on top of each other. Stacking parts like separate robotic modules or control cabinets not only damages fragile surfaces (touchscreens, sensor lenses scratch easily) but can also bend internal structural frames, leading to alignment issues during installation. We recommend leaving at least 12 inches of space around the entire APS for airflow, which prevents dust buildup and helps maintain consistent temperatures around components. Second, security. Automated packaging systems are high-value assets, and even small components like optical sensors (used to detect package dimensions) are targets for theft or damage. We always advise clients to store APS in a locked, restricted access area, with cameras if possible, and to keep a detailed inventory of all small components (sensors, connectors, tools) to avoid missing parts during installation. One of our clients in Texas discovered they were missing a $250 laser sensor after uncrating their APS—turns out a maintenance crew had accidentally used it for a different project, delaying their installation by a week while we shipped a replacement.
Common myths about APS storage persist, and we hear them from clients all the time. Let’s bust the top three. First myth: “If it’s crated, I don’t need to worry about storage conditions.” False. Crates are designed to protect against transit shocks, not long-term temperature or humidity fluctuations. A sealed crate in a 90°F, 70% RH space will develop internal condensation after a few weeks, just like a closed jar of water left in a hot garage. Second myth: “I can store the system in my shipping container, no problem.” Shipping containers are not climate-controlled. In summer, the inside of a shipping container can hit 140°F, which melts plastic components and degrades lubricants. In winter, it can drop below 32°F, freezing hydraulics and cracking seals. Third myth: “Dust is just a cleaning issue.” While cleaning is important, dust is abrasive and can scratch sensor lenses, clog conveyor rollers, and cause electrical shorts—especially in high-humidity environments. Our recommendation is to use a static-proof cloth to wipe down surfaces every two weeks, not just before installation.
At the end of the day, the goal of proper storage isn’t just to avoid damage—it’s to make sure your automated packaging system runs as smoothly on day one of installation as it will 5 years into operation. Every hour of downtime from poor storage costs far more than the extra time and care we outline in our guidelines. If you’re planning an automated packaging system and need help planning your storage space, or have questions about preparing for delivery and installation, our team is ready to walk you through every step. We work with facilities of all sizes, from small e-commerce operations to large consumer goods manufacturers, and we know that a successful project starts long before the first component is uncrated.
If you’re ready to discuss your automated packaging system needs, reach out to our team to schedule a consultation tailored to your facility, timeline, and storage capabilities. We’ll provide clear, actionable recommendations to protect your investment every step of the way.
Automated Logistics References
- International Electrotechnical Commission (IEC) 60079-17: Electrical Installations for Hazardous Areas, 2020
- Packaging Machinery Manufacturers Institute (PMMI) Guidelines for Automated Equipment Storage, 2022
- ASTM International Standard D4956: Practice for Maintaining Industrial Equipment During Storage, 2021
- Automation Federation (AF) Best Practices for Robotic Equipment Storage and Handling, 2020
Zhejiang SUNRISE Intelligent Technology Co., Ltd.
With abundant experience, we are one of the most reliable automated packaging system manufacturers and suppliers in China. Please feel free to buy advanced automated packaging system made in China here from our factory. We also accept customized orders.
Address: Risun Building, 215 Yuanfeng North Road, Fenghua District, Ningbo City, Zhejiang Province, China
E-mail: beijing@sunrise.com.cn
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