As anyone who deals with secondary packaging lines knows, they take up a lot of space. When asked by your boss to estimate the size of your new planned packaging line, the expression on his face when you say, "3,000-6,000 square feet" is priceless. The next question is usually, "Why is it so big?" Simply put, not only are these machines big, but they require ample space for pallets of input components to feed the machines.
Take for example, Oral Solid Dose (OSD) bottle lines. Not only do you need equipment or space for unscrambling, desiccant feeding, tablet counting, cottoning, capping, induction sealing, retorqueing, labeling, cartoning, bundling, case packing, and palletizing (that's 12 machines/work stations if you were counting), but you also need pallets of bottles, tablets, desiccants, cotton, labels, cartons, inserts, and cases. And if you're looking for a quick changeover of that line, all of those components are duplicated in a staging area immediately outside the packaging suite waiting to be brought in for the next lot.
To read more go to http://www.pharmpro.com/blog/2016/04/complex-packaging-compact-spaces