OEM vs. Universal Replacement Parts for Packaging Equipment

What You Need to Know

Packaging equipment is the backbone of manufacturing and distribution operations. Whether you're running a high-speed bottling line or a form-fill-seal machine, the consistent performance of packaging systems is essential for meeting production goals, maintaining quality, and avoiding downtime.

When that equipment breaks down or requires maintenance, you're faced with a critical decision: Should you replace parts with OEM (Original Equipment Manufacturer) parts, or opt for universal or aftermarket parts that may cost less upfront? The answer is not always black and white, but in the packaging industry—where precision, speed, and reliability are paramount—the implications can be substantial.

In this article, we’ll explore the differences between OEM and universal replacement parts, what they mean for your warranty, the risks and rewards associated with each choice, and why most packaging equipment experts recommend sticking with OEM parts for critical repairs.

What Are OEM Parts?

OEM (Original Equipment Manufacturer) parts are components made by the same manufacturer that originally built your packaging equipment. These parts are designed to meet the exact specifications of the original machine and are tested to work seamlessly with other components of that specific system.

Key Characteristics of OEM Parts:

• Exact fit and compatibility: They are engineered to integrate perfectly with the original equipment and the components that surround the part for a seamless repair.
• Tested and certified: OEM parts often go through rigorous quality control and field testing to ensure durability and performance.
• Backed by the manufacturer: In certain situations, parts from manufacturers come with their own warranties or can be covered under the equipment's original warranty if installed correctly.

When you order a replacement sealing bar or a PLC module or any replacement part from the OEM, you can be confident that it is the exact part intended for your machine model and revision.

What Are Universal (Aftermarket) Parts?

Universal or aftermarket parts are made by third-party companies who are not affiliated with the original equipment manufacturer. These parts are designed to function similarly to OEM parts and may be marketed as “compatible” or “equivalent.”

Key Characteristics of Universal Parts:

• Generally lower cost: Universal parts are often less expensive than OEM parts.
• May offer wider availability: Some components can be sourced more quickly or in bulk.
• Variable quality: Quality can range from decent to highly unreliable, depending on the manufacturer. Because the part is made by a manufacturer not affiliated with the original machine manufacturer, it can be hard to trust if proper testing has been performed to ensure that the part will work properly with the system without causing other issues or breaking.

While some universal parts may function adequately for certain applications, others may have slight differences in materials, tolerances, or design that impact performance, especially in complex or high-speed packaging equipment.

Understanding Warranty Implications from Replacement Parts

One of the most important—and often overlooked—factors in choosing OEM vs. universal parts is how your decision affects the equipment’s warranty.

OEM Parts Preserve the Warranty

Most equipment manufacturers explicitly state in their warranty documentation that only OEM parts should be used for repairs or maintenance during the warranty period. This is due to the fact that they have tested their replacement parts and have enough data to show that using their parts will not cause disruption to the machine if installed properly.

Using OEM parts ensures:

• Warranty compliance
• Ongoing technical support from the OEM
• Access to software updates or service bulletins

Universal Parts May Void the Warranty

If you install universal or third-party parts while the machine is still under warranty, you could:

• Void the manufacturer’s warranty entirely
• Be denied claims for future repairs, even if unrelated
• Assume liability for any damage caused by non-OEM parts

Given the higher cost investment of industrial packaging machinery and the potential loss from even a few hours of downtime, maintaining your warranty is critical. If you’re unsure about whether a part will void your systems warranty or may cause further issues, it’s best to reach out to packaging technician to ask questions and get recommendations.

Why OEM Parts Are Often the Better Choice in Packaging Equipment

While universal parts may seem attractive due to their lower cost, OEM parts are typically the better choice for the majority of repairs in packaging machinery, especially in high-precision or automated environments.

1. Designed for Compatibility

Packaging systems often include tightly integrated mechanical and electronic systems. An OEM part is guaranteed to:

• Fit exactly without modification
• Communicate with control systems appropriately
• Perform at the correct operational tolerances

Universal parts may require retrofitting or calibration, which introduces risk and increases labor costs.

2. Higher Quality and Durability

OEM parts are manufactured to the same quality standards as the original machine components. They are made from:

• The same or superior materials
• With the same engineering specifications
• Backed by data from actual field use in your equipment

Conversely, universal parts may cut corners in material grade or manufacturing processes, leading to shorter lifespans or unpredictable failures. While this isn’t the case for all universal parts, it is very common. If you find a replacement part that is nearly half the cost of the same part from the OEM, it’s likely a scenario that’s too good to be true. The upfront cost might look appealing but could cost you more down the road with unplanned downtime due to low quality design.

3. Reduced Downtime

Downtime in packaging operations is costly. OEM parts reduce this risk by:

• Arriving pre-tested and pre-configured
• Minimizing installation time and guesswork
• Eliminating the need for “trial and error” fitting

In contrast, using universal parts may save money initially but can cost more in extended downtime, troubleshooting, and even damage to other machine components.

4. Access to OEM Support

When you use OEM parts, you also maintain access to:

• Manufacturer tech support and engineering services
• Updated part diagrams and manuals
• Remote diagnostics and software tools

This support can be invaluable when dealing with complex systems or recurring issues.

The Hidden Costs of Choosing Universal Parts

Cost savings are often cited as the primary reason to choose universal parts, but it's essential to consider the total cost of ownership (TCO).

Total Cost of Ownership refers to the complete cost of a part or asset over its entire lifecycle—including purchase price, installation, maintenance, downtime, and replacement. In the context of packaging equipment, focusing solely on the initial cost of a replacement part (like choosing a cheaper universal part) can be misleading.

While universal parts may seem more budget-friendly upfront, they often lead to higher long-term expenses due to shorter lifespans, increased machine downtime, and potential damage to surrounding components.

Here are some hidden risks:

1. Performance Degradation

Even small variations in part specifications can lead to:

• Reduced speed or throughput
• Lower packaging accuracy (e.g., sealing misalignments)
• Increased wear on neighboring components

2. Increased Maintenance Frequency

Inferior parts often wear out faster or require more frequent adjustment. This leads to:

• Higher labor costs
• More frequent equipment stoppages
• Greater spare parts inventory overhead

3. Safety Hazards

If a universal part fails catastrophically, it could:

• Create injury risks for operators
• Damage other machine components
• Trigger compliance violations in regulated industries like food or pharma

In safety-critical applications, OEM parts provide an extra layer of confidence.

Be Wary of Discounted Service That Uses Universal Parts

If a third-party service provider offers to lower your maintenance or repair bill by using universal parts, consider it a red flag. While they may present the switch as a cost-saving measure, the long-term risks far outweigh the short-term gains.

Questions to Ask:

• Is the part guaranteed to meet OEM specs?
• Will the service provider take responsibility if the part fails?
• How will this choice impact my machine warranty or service agreements?

Some providers may even install universal parts without disclosing it upfront, especially if they are reselling maintenance contracts at low margins. Make sure your contracts and invoices clearly specify the parts used and their origin.

When Are Universal Parts Acceptable?

While we strongly recommend OEM parts for critical components, there may be instances where universal parts are acceptable:

1. Non-Critical or Peripheral Components

Items such as:

• Bolts, fasteners, and brackets
• Simple gaskets
• Generic sensors or switches

may be substituted if they meet or exceed OEM specifications. Again, there is no such thing as a clear blanket statement when it comes to packaging equipment. These are general examples where substituting a universal part may be perfectly fine and help you save money in repair costs.

It’s best to ask a packaging service technician their recommendation and have a conversation about what impact installing the universal part could have and who would be responsible for correcting any malfunctions as a result.

The Nassco Service Team is available via phone call, or you can submit an online form to ask about particular parts before they’re installed.

2. Out-of-Warranty Equipment

If your machine is out of warranty and the OEM part is discontinued or unavailable, a high-quality universal part may be your only option.

In these cases, we recommend working closely with an experienced maintenance technician who can vet the part and potentially even test it before full-scale operation. Sometimes, manufacturers may also have recommendations for parts that are discontinued and can help you find resources for replacement.

How to Make the Right Decision: A Practical Framework

Here’s a simple decision-making framework to help guide your choice between OEM and universal parts:

Always document your decisions and work closely with your internal quality assurance or compliance teams or your external service provider.

Reliability Should Be Non-Negotiable

In the packaging industry, uptime, speed, and product integrity are the name of the game. Every component in your machinery contributes to those outcomes. Cutting corners with substandard or incompatible parts may save a few dollars in the short term—but it can lead to far more expensive consequences down the line.

OEM parts provide peace of mind. They’re designed for your specific equipment, backed by the original manufacturer, and built to last. While universal parts may have a place in certain situations, they should be used with caution, proper vetting, and always outside of the warranty window.

As a rule of thumb, if your packaging equipment is a mission-critical part of your business, don’t gamble on compatibility—invest in reliability. Choose OEM parts and protect your equipment, your output, and your reputation.