In episode 39 of The Downtime, a weekly manufacturing podcast from WTWH Media, co-hosts Sarah Wynn and Sheri Kasprzak speak with Krupa Ravichandraan, sales product manager at Bosch Rexroth. The discussion covers material handling for consumer-packaged goods (CPG) lines, modular conveyor designs, and how data-driven decision-making is shaping packaging operations.
Designing modular conveyors
When designing for CPG packaging lines, Ravichandraan explained that selecting the best material handling system typically depends on whether a packaging line is being built from scratch or retrofitted into an existing facility.
“If we are looking at a brownfield facility, for example, a customer already has a packaging machine and many times it’s been running for seven or 10 years, and they want to make an upgrade,” he said. “In the CPG industry, we keep changing the bottle sizes, formats, shapes, and speeds.”
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To support these evolving production demands, Bosch Rexroth offers two versions of its VarioFlow conveyor system. “VarioFlow plus is really good for a single file flow of products such as bottles, cans, tubs, trays, even cases,” said Ravichandraan.
Conveyor selection, he added, depends on product flow and application requirements. “The VarioFlow belt is a much wider belt, stronger,” he said. This design accommodates larger projects, such as toilet paper and paper towels, as its side rails can be adjusted to different formats.
Both VarioFlow systems largely serve the CPG industry and are engineered with aluminum framing, which provides reconfiguration benefits.
“Predominantly, we use aluminum framing, which allows the manufacturers to change the width and the length with ease when you compare it to a stainless-steel conveyor, which is more custom-made,” said Ravichandraan.
That modularity helps machine builders reduce redesign time while supporting sustainability goals. “You’re not throwing away a lot of parts, you’re reusing parts,” he said.
Using data and sensors to extend conveyor life
Extending the lifecycle of a conveyor was another point of emphasis from Ravichandraan. He explained that manufacturers are using data from sensors to monitor vibration, temperature, and force, which can then be paired with analytics to support more informed decisions.
“You’re getting the data. But then the challenge for even larger manufacturers was, ‘How can I convert this data to make better decisions?’ That’s where AI comes in,” he said. “They can quickly adapt, plug and play, convert the data into visual formats that the managers and operators can see, and make real-time decisions quickly.”
Ravichandraan shared an example of a long-time VarioFlow customer that introduced a heavier container to an existing line. With increased weight and repeated impacts at transfer points, chain links began cracking over time.
“That could have been avoided if there had been a sensor attached to the chain or some kind of inspection device,” said Ravichandraan. “It could be a camera inspection device as well to see the gaps in between the chains, which could be coded back into the system to determine anomalies.”
Automation across CPG plants
Ravichandraan also addressed how small, mid-sized, and large CPGs are approaching automation differently. He emphasized that larger end users are looking to make plant layouts more modular and compact.
“So that when I introduce a new product line, I’m not putting in a completely new line. Instead, I’m using some of the equipment, rearranging them, and making sure I use less amount of new capital to optimize what I have on the plant floor,” said Ravichandraan, regarding large CPGs’ approach to automation, which requires the ability to collect and analyze data.
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Ravichandraan also addressed the perspective on small and medium-sized end users in terms of automation.
“The bottom line is to increase their throughput, increase their efficiency, keep the production flow running, don’t stop the machines,” he said. “That’s what they’re more concerned about.”
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Sunrise 2027 implications for packaging lines
With Sunrise 2027 on the horizon, the industry’s date to transition to accepting 2D barcodes at point-of-sale systems, Ravichandraan said, its impact is already reaching packaging lines.
“We are seeing, because of regulatory requirements, people moving from 1D barcodes to more of a 2D, QR scan code,” he said. “That’s happening immediately, not sometime in the future.”
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Ravichandraan encouraged OEMs to ensure coding, inspection, and conveyor handling can maintain print quality, package orientation, and readability of these 2D codes at line speed.
Episode 39: The Snow Must Go | Show notes & time stamps
00:17 – The co-hosts open the show
01:52 – Wynn shares Packaging OEM’s story on 2026 U.S. packaging laws and regulations that machine builders need to know
02:31 – Kasprzak highlights a story from Plant Engineering on NFPA 70E and OSHA electrical safety standards
03:38 – The co-hosts introduce this week’s guest, Krupa Ravichandran, sales product manager at Bosch Rexroth
04:22 – Interview with Ravichandran begins
10:26 – Ravichandran explains integrating modular conveyors with existing packaging machinery.
15:11 – The trio discusses AI, sensors, and Industry 4.0 in material handling
22:05 – Ravichandran explains how automation is changing plant jobs and roles
27:18 – Ravichandran shares 2026 material handling trend predictions. The co-hosts also share Packaging OEM and Plant Engineering trends
29:55 – Interview with Ravicandran ends
30:26 – “Slay or Convey” winter‑themed game segment starts
32:59 – The co-hosts wrap up the show and share where listeners can find The Downtime online
About The Downtime podcast and co-hosts
The Downtime is a weekly manufacturing podcast from WTWH Media that features insights from its automation and controls publications. It’s co-hosted by Wynn, who serves as the senior editor (digital) for Packaging OEM, and Kasprzak, who is the executive editor for Plant Engineering, Control Engineering, and Consulting-Specifying Engineer.
The podcast is available weekly on YouTube, SoundCloud, and Spotify.
Check out The Downtime’s recent episodes
Episode 34: Wrapping up packaging and manufacturing trends for 2025
Episode 35: Schneider Electric on AI, robotics, and digital twins in packaging
Episode 36: How Weintek’s HMIs act as a “universal remote” for packaging OEMs
Episode 37: CAPTRON on sensing technology for washdown environments
Episode 38: Festo on safety-integrated servo drives for packaging
