WHAT ARE CARTONING MACHINES?

Preface

ELITER Packaging Machinery has been dedicated to the design and manufacturing of cartoning machines for generations. We would like to share with you our knowledge obtained throughout our business with regard to what are cartoning machines and all the related topics of such a carton packaging equipment.

The cartoning machine, also known as a cartoner packaging machine, is a prevailing type of packaging machine among the various automated packaging equipment available in the market.

The primary objective of this guide is to provide customers with a comprehensive and thorough evaluation of automatic cartoning machines, enabling them to make informed purchase decisions during the procurement process.

We have emphasized the significance of acquiring qualified and reliable packaging machinery, as well as highlighted the adverse consequences of purchasing an inadequate machine which may include

• ongoing labor and technical maintenance costs,
• the need for machine replacement or additional purchases if reliability is compromised,
• and potential disruptions in production that could have severe implications for one’s business.

In addition to focusing on the machine itself, this guide also incorporates information on the packaging materials involved, such as the assortment of cartons available and the methods of closure and sealing. By considering their specific requirements and product specifications, readers can assess the most suitable automatic cartoning machine for their particular project.

Work with ELITER Packaging Machinery for High-End Cartoners

ELITER Packaging Machinery is a family-owned business in the packaging automation and machinery industry. Going through a stage of transformation, we are constantly investing in the r+d+i of next-generation models to meet the expectations of customers from high-end markets who are particular about quality. Our next-generations cartoners are tailed with all the modern features of how a high-end cartoner should be and can sell to the European market.

Gran-Sonata Balcony Cartoner

Gran Sonata Balcony Cartoner

Next-generation cartoner designed and manufactured with European quality.

Balcony caronter that allows improved convenience for maintenance and cleaning.

Features: Intermittent motion, fully servo driven with SIEMENS control platform, washdown to IP65

Crescendo Cartoner

Crescendo Cartoner — with Duet 200 Loading System

Next-generation cartoning machine with smart loader system incorporated with servo technology and motion control system.

Features: Continuous motion, high speed, innovation high-speed cartoning

Why are Cartons the Most Popular Form of Packaging?

When observing the assortment of products found on the shelves of supermarkets, pharmacies, and cosmetics stores, it becomes evident that the majority of items are packaged within cartons.

The use of cartons as a popular form of packaging can be attributed to several factors. Firstly, cartons provide a sturdy and protective structure for products, preventing damage during transportation and storage. It is such a solid packaging that offers cushioning and insulation, ensuring the integrity and safety of the items within.

Cartons are versatile and can be customized to accommodate a wide range of products, and further, they can be designed in various shapes and sizes, allowing for efficient packaging of different items, from small goods to larger products. Cartons do not always follow the design pattern of being a solid square object, nevertheless, cartons can be tailored with features such as dividers, inserts, and windows to enhance product visibility and organization.

Tea Herb Carton by Monos Foods
Credit: Monos Foods

Cartons demonstrate a lightweight construction and cost-effectiveness. Their compact design facilitates convenient stacking, optimizing storage capacity and minimizing transportation expenses. The lightweight properties of cartons also contribute to their eco-friendliness, requiring less energy and resources during the production and transportation stages in comparison to alternative packaging materials.

The fact that cartons come with 6 panels allows more space of printing and displaying information that allows cartons to present favorable avenues for branding and marketing endeavors. They offer the capability to showcase high-quality graphics, logos, and pertinent product information, effectively augmenting the visibility and desirability of the packaged item when positioned on store shelves.

What are Cartoning Machines?

Cartoning machines or cartoners, refer to such automated packaging equipment integrated with specific kinematics and mechanisms to automate the process of inserting or loading various products into cartons and is utilized in packaging lines aligned with various packaging machines like HFFS, VFFS and overwrapping machines and case packers. These machines play a pivotal role in ensuring the efficiency and accuracy of packaging operations.

From a mechanical engineering perspective, cartoning machines involve intricate kinematic systems, which govern the motion and coordination of their components for which reason frequently such machines employ a combination of rotary and linear movements to accomplish the tasks of product feeding, carton erection, product insertion, flap closure, and carton sealing. The kinematic analysis of a cartoning machine reveals the utilization of mechanisms such as cams, linkages, gears, and belts which are employed to convert input rotary or linear motion into the desired functional movements required for the various stages of carton packaging.

The Rotary Feeder of Cartoner Follows Rotray Motion
Credit: ELITER Packaging Machinery

For instance, the carton erector serves as the mechanism responsible for erecting cartons and involves the use of cams and linkages. As the carton blanks are fed into the machine, the cam-driven mechanism guides the blank through a series of pre-determined motions, ensuring its proper folding and shaping into a carton structure. Alternatively, in the case of continuous motion cartoner, the carton feeder follows a rotary motion pattern and is designed specifically on a star gear system which is rather more complex than linkages and can reach up to a faster speed.

Tuck-in Station of Cresecndo Cartoner
Credit: ELITER Packaging Machinery

The product insertion stage typically relies on a combination of linear and rotary movements. A product feeding system delivers individual items to a designated location, where a robotic arm or a mechanical gripper picks up the product and precisely places it into the awaiting carton. This process demands careful coordination of motion, speed, and position control to ensure accurate placement of the product. The closing and sealing of the carton involve kinematic mechanisms that facilitate the folding of flaps and the application of adhesive or mechanical fasteners to secure the carton’s closure. The extend to which the cartoning machine is consistent with the packaging performance and precision of packaging sealing relies tremendously on how these sections are well constructed.

Operational Sequence Diagram of Cartoning Machine
Credit: ELITER Packaging Machinery

What is the Structure of a Carton?

Cartons come in a considerable variety of shapes and forms which subsequently will determine the level of personalization of carton solutions. In this chapter, we talk about cartons to leave an essential foundation for our further topic of cartoning solutions. We will focus on End-Load cartons only and not extend to a thorough discussion of carton package.

In the very beginning, we shall first introduce two concepts:

PANELS: Cartons are all in cubic and cuboid forms. When it is closed it appears as a complete cubic consisting of 6 planes which are called the Panels. Panels are categorized into:

1. Front Panel

2. Rear Panel

3. Leaf Side Panel

4. Right Side Panel

5. Top Closure Panel

6. Bottom Closure Panel

FLAPS: Basically Flaps are those parts that help to maintain the form of carton when it is closed and they are fixed in the inner part of it when carton is closed. Flats can be divided into three categories:

1. Tuck Flaps — those are adjacent to the panel on the end side and are inserted into the carton to close it.

2. Dust Flaps — the two relatively small flaps on the end side. There should be four dust flaps on a carton

3. The Glue Flap — a carton magazine is formed into a carton with the Glue Flap connecting two ends of it.

The Closure of Glue-Sealed Carton on a Cartoning Machine
Credit: ELITER Packaging Machinery

II.I Tuck End Carton

A tuck end consists of a Closure Panel and a Tuck Flap, accompanied by Dust Flaps on the two sides. This is the most popular form of carton style that you must know. The tuck end carton can be classified into two types: Straight Tuck End Carton and Reverse Tuck End Carton.

Straight Tuck End or STE Carton: A carton with a top and bottom that both tuck into the same side of itself.

Reverse Tuck End or RTE Carton: Literally, this is a carton with a top and bottom that both tuck into the different side of itself.

A comparative image is as follows so that you can have a vivid view of these two types of tuck end cartons.

II.II Snap-Lock Bottom and Auto-Bottom

A Snap-Lock Bottom is also known as a 1–2–3 bottom for its ways of being closed. Three flaps are folded for closure and form a rather more stable structure.

An Auto-Bottom is a self-supporting structure that when the carton is erected, the flaps and panels pop on the bottom pop into place making itself a closure structure simple, quick and stable.

II.III Seal-End Carton

Seal-End is usually used for loading heavy and large-size products. We must have seen such a structure on items such as cereal and muesli you have for breakfast.

The two closure panels are sealed by glue and usually, a batch code is printed on the outer panel. In case the two end side of the carton are all seal-end, the Top Seal-End will also be left with a perforation Line for purpose of tear.

Here at the end of this chapter, we’d also like to mention that end load cartons may possibly come in a form that the previously mentioned structures are combined. As following are some examples of this hybrid: Tuck Top AutoBottom, Tuck Top Seal-End Bottom, Double Seal-End, etc…

Straight Tuck-End

Straight-Tuck End Carton (STE) or Aeroplane-Tuck Carton is one of the most common styles of carton, the closure panel are with the same panel

Reverse Tuck End

Reverse-Tuck End Carton is just like the STE while the closure panels are with Rear and Front Panels.

Glue-Sealed Carton

Cartoning machines for glue-end cartons should be joined by a glue melter to seal the carton. Glue-end cartons are without tuck-flaps while the closure is done and sealed with hot-melt-glue.

Hanger Carton

Hanger carton box is a style of carton with typical hanging tabs on which there are openings for the purpose that they can be hung on shelves.

Gable Top Carton

A gable top carton is featured by its pyramid-like top structure where to two side panels are fold in and then one closure panel is folded to cover another with and sealed with hot-melt-glue or with tuck inserted.

Snap-Lock Bottom

Snap-lock bottom is known as well the 1–2–3 bottom. It is a popular and easy-folding carton style bottom whose flaps are interlocked to form and safe and tight closure.

Auto-bottom Carton

Auto-bottom carton is a style of carton with self-support bottom whose flaps or panels are automatically interlocked with the carton blank is erected.

Pre-Glued Sleeve

Sleeves are without any flaps or closure panels. The pre-glued sleeve is just like the carton into where the products are inserted horizontally by end-side.

Cereal Box

A larger version of glue-sealed carton, however, with closure panel designed with a tearing line and also combined with tuck tab for reclosure. Bottom of cereal box is usually the auto-bottom or snap-lock bottom to maximize the solidity.

Pillow Box

Pillow boxes, also known as pillow gift box, are often used for gift packaging. It is featured by the simple, sleek and elegant shape and appearance.

Wrap-Around Sleeve

Completing the carton sleeving packaging on the cartoning machine is not a big deal.
ÉLITER Packaging Machinery offers unique sleeverand wrap-around cartoning solutions for either single container or multipack of containers.

Tuck and Tongue

Tuck and tongue boxes are typical for their solid structure to withstand abusive handling. This is an ideal carton style for delicate products.

How Packaging Automation Reduces Packaging Cost per Unit?

Should a producer solely rely on labor for production, an increase in desired production would necessitate a corresponding increase in labor.

Consequently, this escalation in labor requirements would demand larger workshop spaces, thereby resulting in higher land costs. It is postulated that there exists a linear relationship between production quantity and unit cost, as depicted in the graph on the left.

Nevertheless, in the event that a cartoner or any other packaging machine (irrelevant as it pertains to our current hypothesis) is installed in the workshop, the unit cost of packaging production will commence at the price of the machine upon the production of the first unit.

Recommended Reading:

When is the time to automate packaging process?
When labor cost is constantly increasing while you are still not able to fulfill the orders and demands, it is time to consider packaging automation.

Subsequently, the cost per unit of packaging will decrease rapidly with increasing quantities. Even if the producer seeks to enhance production further by acquiring and installing additional machines, the initial costs will be higher; however, the requirement for greater workspace will be relatively diminished in comparison to labor-intensive operations, resulting in reduced costs.

Correlation of Cost per Packaging and Quantity
Credit: ELITER Packaging Machinery

What are the Different Types of Cartoning Machines?

The types of cartoning machines can be defined in accordance to the loading patter, motion, and operational sequence.

End-Load Cartoning Machines

An end-load cartoning machine is a type of packaging machinery specifically designed to load products into cartons through the end or side opening. These machines automate the process of inserting products into cartons, providing efficiency and accuracy in packaging operations.

End-loading can either be horizontal or vertical, the key concept here is that the loading of products takes place from the facet where the panel is relatively smaller in square area rather than from the side of larget panels.

End-Loading of Blisters into Carton
Credit: ELITER Packaging Machinery

Recommended Reading:

How to operate a horizontal end-load cartoner?

Top-Loading Cartoning System

The top-loading cartoning machine is actually a integrated system that has the products loaded from the facet of larger panels.

The forming from flat-blank method + top loading is a relatively complex approach to cartoning that calls for an integration of at least the following 5 sections:

• Carton tray former
• A linear product transport system
• A collator system
• A delta robot or so
• A Carton Sealer (tri-sealer)

Top-Loading Pattern of Cartoning
Credit: ELITER Packaging Machinery

Intermittent Motion Cartoner

An intermittent motion cartoner is a type of packaging machine that operates in a start-stop or intermittent manner.

During the packaging process, products are introduced into the cartons at the required intervals. This can be done through mechanical arms, feeding systems, or other mechanisms that ensure accurate and precise product placement. After product insertion, the carton is sealed, and the process repeats with the next carton.

Intermittent motion cartoners are known for their versatility and flexibility in handling various product sizes, shapes, and configurations. They can accommodate a wide range of packaged products, including bottles, tubes, blister packs, pouches, and more.

An old model of intermittent motion cartoner by ELITER
Credit: ELITER Packaging Machinery

Continuous Motion Cartoner

Unlike intermittent motion cartoners that function based on start-stop cycles, continuous motion cartoners offer a more streamlined and uninterrupted packaging process, allowing for higher production speeds and increased efficiency.

The continuous motion of the cartoning machine is achieved through synchronized mechanical drives and conveyor systems. These systems ensure smooth and constant movement of the cartons and products, reducing any delays or interruptions in the packaging process.

Continuous motion cartoners are known for their high-speed operation, allowing for increased production rates and improved productivity. They are commonly used in industries that require large-scale packaging, such as food and beverage, pharmaceuticals, and personal care products.

Continuous Motion Cartoner Crescendo
Credit: ELITER Packaging Machinery

Recommended Reading:

What are the pros and cons between continuous and intermittent cartoning machines?

Cartoning Machine for Bespoke Packaging Automation

The goal of a cartoning machine for bespoke packaging automation is to provide manufacturers with the flexibility and efficiency to package products in unique or customized cartons. These machines streamline the packaging process, reduce labor requirements, and ensure consistent and reliable packaging quality for tailored or personalized products.

For example, intermittent cartoning macine can be customized to fit unique a special carton styles with securing tabs, neck-through pattern, and even for wrap-around sleeve cartoning.

De’Xandra Perfume Cartons
Credit: De’Xandra

Structure and Workflow of Cartoning Machine

Regardless of the fact that cartoning machines are defined into several types, their working processes are actually “potato potahto”. Basically, a cartoning system would erect carton blanks, insert products into the carton, and close the loaded carton.

The following content will offer an overview of how a cartoning system or machine works and some introduction to the corresponding structures.

The Bucket Conveyor

The bucket conveyor consists of a pair of separate moving chains. The bucket conveyor is capable of moving the products in buckets from the loading hand to the feeding section. In some cases, the two chains are controlled by servo motors so as to automatically adjust gaps and distance between each bucket to fit to another project and thus to complete the changeover. The process is done only by setting the configurations on the touch screen.

Carton Magazine or Carton Hopper

A carton hopper or carton magazine is a station on the machine that holds a pile or a stack of flat carton blanks which are unfolded. The carton erector will pick the blanks from the hopper one by one and then fold them into erected cartons. On the carton hopper there are usually several photo eyes installed to withstand and monitor the level and quantity of carton blanks left in the hopper. For example, a low carton photo eye is installed to warn against the situation when carton blanks are just about to be used up. When the alert is triggered, the machine usually would reject to working until new blanks are filled and placed into the hopper.

Carton Erector or Picker Assembly

The carton erector or the picker assembly is such a section to which the most innovations those manufacturers of cartoning machines attach to.

Carton blanks are to be picked by the picker or suction panels on the picker assembly which is connected to air. The erector can either be servo-driven or mechanical driven depending on what cartoner it is and by which manufacturer it is made.

Vacuum is applied to the suction panel on the assembly once, during the rotation, it gets in contact with the carton blank into carton hopper. Thereafter, the picker places the carton onto the lug chains of the carton transport for discharge after going through a series of guides that help to force and open the blanks in order to fold them into erected cartons.

Export Conveyor, Carton Transport

The export carton transport conveyor consists of a pair of lug chains. The carton is placed and secured between them. The space is always fixed according to the size of the carton. When it is supposed to adjust and carton size on the cartoning machine for format changeover, one of the lug chains should be adjusted in order to widen or narrow the space between the chains.

Insertion Station

Once the carton has been opened and erected, the packages of material carried on the bucket conveyor are going to be inserted into the folded and opened cartons. There can be a single insertor that pushes the packages or materials on an intermittent basis or a series of barrel loaders that push them into the carton in a continuous manner.

Flap Folding and Tuck-In Station

In the case of tuck-end cartons, a station is nearby the discharge station to fold the dust flaps and complete the tuck-in in order to close the carton.

Discharge Station

The discharge station consists of a pair of time belts that secure the closed carton and takes them out of the cartoning machine.

Cartoning machines, PLC, SCADA, and Factory Automation

What is SCADA?

SCADA, which stands for Supervisory Control and Data Acquisition, is a system used to monitor and control industrial processes. It typically consists of a combination of software and hardware components that collect and analyze data from various sensors and devices, allowing operators to remotely monitor and control these processes from a centralized location.

In the context of a cartoning machine, SCADA can play a role in the overall packaging automation system. Here’s how SCADA can be related to a cartoning machine:

• Monitoring and Control: SCADA systems can monitor the operation of the cartoning machine in real-time. It can gather data from sensors and devices embedded within the machine, such as motor speed, conveyor movement, and carton supply levels. This data can be visualized through the SCADA system’s human-machine interface (HMI), allowing operators to monitor the machine’s performance and detect any abnormalities or potential issues.
• Process Visualization: The SCADA system can provide operators with a graphical representation of the cartoning process. The HMI can show live status updates, display real-time operating parameters, and provide visual indicators of the machine’s performance. Visualization enables operators to have a clear overview of the cartoning process and facilitates decision-making and troubleshooting.
• Automation and Control: SCADA systems can control certain aspects of the cartoning machine’s operation. Through the HMI, operators can adjust settings, modify parameters, or initiate automated actions, such as starting or stopping the machine, changing packaging formats, or adjusting carton collation patterns. SCADA allows for precise control and efficient operation of the cartoning machine.
• Data Analysis and Reporting: SCADA systems collect and store data from the cartoning machine, which can be analyzed later for performance optimization and process improvement. Statistical data, such as production rates, downtime duration, or error rates, can be examined and used to identify trends, make informed decisions, and implement preventive measures.
• Integration with Overall Packaging Line: In a packaging automation setup, the cartoning machine is often just one component in a larger packaging line. SCADA systems can integrate and communicate with other machines, such as filling machines, labeling machines, or sealing machines, to ensure synchronized operation and efficient coordination. This allows for seamless control and monitoring of the entire packaging process.

By incorporating a SCADA system into a cartoning machine, operators can benefit from enhanced monitoring, control, and analysis capabilities, leading to improved productivity, efficiency, and quality in the packaging process. SCADA systems provide real-time insights into machine performance, enable proactive control, and facilitate data-driven decision-making, ultimately enhancing the overall automation and effectiveness of the cartoning machine.

Taking a double-bottle cartoning machine as an example

In the context of factory automation, the PLC is the most used machine controller regardless of the industry. Especially in the case of the cartoning machine, which is usually installed in an assembly line, the application of PLC helps to boost production and quality of the production.

While PLC is the core factor of the total processes of supervisory, data acquisition, process control, and so forth, there is always a circumstance where something unpredicted may occur and due to which a machine breakdown is led to. For example, on a cartoning machine, the box fails to be folded, the insertion is hurdled, or there is a lack of carton blanks… etc. All the above cases call for an interface where people can handle the situation and proceed to troubleshoot and recover from the downtime.

Industrial professionals and engineers usually get this done by:

Utilizing a human-machine interaction panel (HMI) which has been programmed and can coordinate with various data acquisition and supervisory devices on the cartoning machine to render supervisory on the functionality of the cartoning machine and thus improve the production process.

We discuss in this blog how such a system is achieved on a cartoning machine by analyzing step by step and part from part.

The Basic Logic Between the Cartoner and PLCs

Regardless of the fact that the cartoning machine can either be fully automatic or semi-automatic, the cartoning machine works with optics, electricity, air source and mechanisms which are controlled by the PLC to work smoothly. The data acquisition, or say the detection of physical parameters is realized through various sensors installed on the cartoning machine. After that the data has been sent to the PLC, the program handles them to verify the status and situation of the machine and send feedback, if necessary, to the actuators such as solenoid valve, glue melter, leaflet folder, etc to complete the corresponding actions regarding the situation and circumstance.

So, to put it in a word, it would be something like:

Physical Parameter → Sensors → PLCs → Actuators → Actions and Further Physical Parameters

which finally forms a loop during the operation of the cartoning machine.

The Basic Working Process of a cartoning machine

A cartoning machine can be used either separately or connected with upstream machinery such as a blister packaging machine or a cupping machine to form a packaging line. Here we take a double bottle cartoning machine connected upstream for the cartoning of bottles as an example.

The Basic Working Process and Functions of Cartoning Machine

1. Infeed of Products (Bottles)
2. Product Detection (Achieved by photo-eye)
3. Leaflet Infeed
4. Detection of leaflet (Achieve by photo-eye)
5. Carton Hopper or Carton Magazine
6. Carton Blanks Level Control (by photo-eye)
7. Carton Picker (or carton feeder)
8. Detection of cartons loaded on the chain
9. Closure of dust-flaps
10. The transfer chain (for discharge)
11. Pushrod
12. Closure for Tuck-in
13. Discharge Station

Product Infeeding (the case of a double bottle cartoning machine)

The machine is connected with an infeed conveyor on which bottles are collated and fed one by one to the infeed wheel. A bottle sensor is there to detect whether the primary bottle is already loaded on the bucket conveyor and confirm its presence. The system is synchronized with the help of the servo motor, PLC and the photo-eye to ensure for each primary bottle loaded on the bucket chain the infeed wheel will place a corresponding second bottle on the bucket conveyor.

Leaflet Infeeding

The machine is installed with a leaflet folder on which there is a hopper to store the leaflet blanks. The leaflet is folded the carried by a conveyor which is parallel to the bucket conveyor aligned with infeed of bottles. A photo eye supervises whether the leaflet has been folded and fed to the chain with success and if not, sends signals to PLC for rejection afterward.

Carton Feeding

The cartoning machine is equipped with a carton hopper where carton blanks are to be picked up, folded and erected on the conveyor. The carton magazine is often installed with a minimum load photo-eye to detect whether there are enough carton blanks loaded in the carton hopper. While bottles are moving down being loaded on the bucket conveyor, the carton feeder picks and erects carton blanks onto the corresponding position on the conveyor for the correct insertion afterward. This process is realized by air source by the coordinator between photo-eye, solenoid valve and PLC.

Troubleshooting Guide for Cartoning Machine

It is not a rare situation where cartons are torn during the working process of the cartoning machine. Follow this chapter to determine where did the problems originate and solutions to get the problems eliminated.

Damage on Carton’s Leading Corners

• Check the vacuum of the carton feeder. The possible cause of the rips might be that the vacuum has been too strong at the point when carton is just about to be secure on the lug chain yet it is still dragged by the vacuum, thus leading to tearing on the leading corners of the carton
• Check the overhead gudie of the cartoner. The rips might be casused due to the squeezing between carton and the overhead guide

Damage on the Trailing Side of the Carton

• Check the timing when carton is secured on the lug chain
• Check the tightness of lug chains

Damaged and Unfolded Dust-Flap

• Check the position of the dust-flap folder after the loading of carton on the lug chain
• Check the position of flap securing guides
• Check whether the length of the dust-flap corresponds to that of the carton the cartoning machine was designed for

Wrinkles on the Side Panel

• The overhead guide has been set with an extra low level that squeezes the carton downwards
• Check the lug chains and make sure that they are not set with an extremely short distance

Criterion of Selecting a Qualified Cartoning Machine

Choosing a qualified cartoning machine is a critical decision that requires careful evaluation and consideration of various factors. As mechanical engineering professionals, understanding the key criteria for selecting a cartoning machine is essential to ensure optimal performance, productivity, and cost-effectiveness. This article aims to explore the crucial criteria one should consider when selecting a cartoning machine from a mechanical engineering perspective.

• Packaging Requirements and Flexibility:

First and foremost, carefully analyze your packaging requirements to determine the suitability and flexibility of the cartoning machine. Evaluate factors such as package size, shape, weight, and the type of product being packaged. Consider whether the machine is capable of handling various packaging formats, such as bottles, pouches, or cartons. A qualified machine should accommodate a range of packaging specifications to meet different product demands.

1. Machine Speed and Performance:

Evaluate the speed and performance capabilities of the cartoning machine. Consider the desired production output, packaging cycle times, and overall efficiency requirements. Review the maximum cartons per minute (CPM) rating of the machine to ensure it aligns with your production goals. Additionally, look for features that enhance machine reliability, such as robust construction, advanced control systems, and efficient power transmission mechanisms.

1. Mechanical Design and Ergonomics:

Assess the mechanical design of the cartoning machine to ensure it promotes ease of use, maintenance, and operator safety. A qualified machine should have a sturdy frame and well-engineered mechanical components to withstand the demands of continuous operation. Evaluate the accessibility and ergonomics of key machine elements, such as the carton magazine, feeding system, and conveyor belts, to facilitate efficient operation and maintenance procedures.

1. Automation and Control Systems:

Consider the level of automation and control systems integrated into the cartoning machine. Automation features, such as servo-driven mechanisms, programmable logic controllers (PLCs), and human-machine interfaces (HMIs), improve accuracy, speed, and versatility. Advanced control systems enable precise adjustments, efficient changeovers, and real-time monitoring capabilities that enhance overall performance and reduce downtime.

1. Reliability and Maintenance:

Reliability is a crucial criterion for selecting any machine. Carefully review the reputation and track record of the manufacturer in terms of machine reliability and durability. Analyze the maintenance requirements and accessibility of critical machine parts, such as cutting and sealing tools, to ensure easy troubleshooting, servicing, and replacement. Consider the availability of technical support, spare parts, and the manufacturer’s commitment to customer assistance.

1. Compliance with Standards and Regulations:

Ensure that the cartoning machine aligns with industry standards and regulations, such as Good Manufacturing Practices (GMP) and safety guidelines. Look for machines that comply with relevant standards for electrical safety, hygiene, and product integrity. Verification of compliance with regulatory bodies, such as the FDA (Food and Drug Administration) or ISO (International Organization for Standardization), adds credibility and ensures product quality and safety.

Selecting a qualified cartoning machine requires a systematic evaluation of various criteria from a mechanical engineering perspective. Analyzing packaging requirements, assessing machine speed and performance, considering mechanical design and ergonomics, evaluating automation and control systems, assessing reliability and maintenance aspects, and ensuring compliance with industry standards are vital considerations. Through a comprehensive analysis of these criteria, mechanical engineers can make informed decisions, ensuring the selection of a cartoning machine that optimizes productivity, efficiency, and long-term operational success.

How to Find a Reliable Cartoning Machine in China? — We have 4 Tips for You

Finding a supplier of cartoning machines in China is just a piece of cake. With a random search on search engines and those B2B platforms like Alibaba and Made-in-China we can soon get mountains of companies at our options no matter if they are real manufacturers of trading companies.

Just like any “Red Ocean” market section, the one of caroning machine is of complete competition that a majority of the buyers would focus on price to make the decision of purchase, however, some tiny details people without background or knowledge around mechanical engineering may look over yet enact as critical factors for a successful implementation of the project and for long-run reliability of such an automated system.

Are you looking for your cartoning machine for the first time?
Read our guide for you to find out expert tips!

Among all the secondary packaging machines and to review from the market share and portion and each type of them takes over this sector, cartoning machine is no doubt the category that is mostly widely used and sought by customers from all range of industries.

No matter whether you are from high-end markets like Europe or North America, or you may look to source an affordable option and pay great importance to the price, the concerns around buying a cartoning machine are basically the same — ensure a successful implementation. We hereby provide some insider tips and factors you should consider to find the right cartoning machine for your business.

Be Prudent with Low Price and Cheap Cartoning Machines

“Each buck counts for the quality.”

It would be like some kind of “daydream” but something everyone really looks forward to — European Quality at a Chinese Price, which is by no means something reasonable. In the past blog, we have discussed the downsides of “cheap cartoning machines” and we have studied how a low-quality cartoning machine is priced by looking through different concepts.

Cheap machines have their reasons to be low-priced. They could be made with the concession to quality, versatility, functions, safety, and durability.

There are several risks associated with cheap cartoning machines:

• Quality Issues: A typical quality issue with low-priced cartoning machines is the redundant use of coated and galvanized iron parts in stead of robust and solid stainless steel components. It is reasonable in order to keep the raw cost as low as possible now that a same part would 4 times more expensive if made of SUS compared to being processed as coated iron.
• Lack of Versatility: Cheap machines may have limited capabilities and be suitable for only specific types and sizes of cartons. This can restrict the range of products that can be packaged using the machine, limiting flexibility and scalability.
• Safety Issues: Cheap machines may not have the necessary safety features and mechanisms to protect operators from accidents and injuries. This can increase the risk of workplace accidents and potential legal liabilities.
• Higher long-term costs: Although the upfront cost of a cheap cartoning machine may be low, the long-term costs can be higher due to frequent breakdowns, increased maintenance, and reduced productivity. Investing in a higher-quality machine initially can often result in lower overall costs over the machine’s lifespan.

Consider the Output of your Existing Packaging Equipment

Though some would purchase a machine and use them in the form of stand-alone, secondary packaging machines are usually supposed to be connected to primary packaging machines like VFFS, HFFS, filling machines, automatic baggers, thermoformers, tray sealers, etc. The integration of a cartoning machine into your existing packaging equipment, if done correctly, can bring perfect automation without compromising its capacity.

The cartoning machine should be the additional equipment that provides automated packaging solutions to extend your packaging process rather than being such a bottleneck that will drag down your overall ROI of the line.

Defining whether a cartoning machine is correctly your option, you should consider the following factors:

Can the cartoning machine keep pace with inflow speed?

Theoretically, the cartoning machine must be faster the than configured speed of your existing equipment, rather than offer an exactly matched speed. This is not only to ensure that the cartoning machine does not become the bottleneck but as well to avoid congestion along the packaging line.

Consider the pattern of outflow from your existing equipment

A specific kind of cartoning machine will have limited capability in handling inflow in terms of the pattern they are coming in. For example, a vertical cartoning machine can be incorporated with a VFFS directly in a way that the formed bags can drop directly into the box from the vertical open end, while this is impossible for a horizontal end-load cartoning machine.

Don’t Complicate Things — a Standalone Cartoning Machine Can be Better

Implementing automation is a good option to save manual and labor costs. Nevertheless, the mania with automated packaging can result in a more complicated situation where you will be spending more money without much improvement in terms of savings or packaging efficiency.

It happens that a standalone machine would be better than having your production line fully automated.

We once handled a project for which the client asked to automate their process starting from an 8-lane VFFS from which bags of powder are discharged in a random manner.

The requirements were:

• Install a system that arranges the bags in an organized manner — with a bag unscrambler
• Stack the bags into the desired format and feed them onto a cartoning machine
• A cartoning machine that packs the bags into boxes

The complete line costs some USD 90,000 but little improvement is seen in terms of output, since the bag unscrambler eliminates bags that are in unwanted direction on the inflow and thus causing a bottleneck. Then the factory still needs bunches of people to monitor the machines and systems involved in this line.

On the contrary, should we adopt a standalone cartoning machine with a bag and sachet feed and stacking system on which the operator is supposed to load bags manually, we can expect all the bags to be fully automated for the cartoning and look forward to better output.

Audit Your Cartoning Machine Supplier and Make Sure They are Reliable

• “We are the leading manufacturer”
• “We have a factory of 6000 square meters”
• “We have 20 years of history”
• “We install 1,000 equipment every year”
• “We are a factory”

If you ask any company in China whether they are a factory or a trading company and reseller, you will always get the same answer — “We are the factory”.

We are not addressing this issue in a way that you should work with the factory only and avoid resellers. The key idea with this suggestion is to avoid working with dishonest suppliers — who cheat and lie to you ever since the very beginning.

The popular trick of them is placing photos of factories, workers dressing in uniform with company logos as well as machines with logoed labels so as to give an impression that they are the manufacturer, but unfortunately, all such seemingly convincing proof can be fake in fact.

Be Careful with Cheap Chinese Cartoning Machines — Here are the 4 Reasons

China — the Eastern Supremacy, is the dominating country of export in the field of manufacturing ever since its membership in the Word Trade Organization, as well as in the sector of packaging automation and packaging machines is China one of the leading exporters in the world.

Among all sorts of packaging machines, the cartoning machine is probably one of the most popular machines, and the market of which is already a Red Ocean that there are mountains of suppliers and manufacturers at your option. However, no matter whether you are a machinery dealer or a final user who is looking for a cartoning machine made in China, there are some hidden facts that people who do not work in the sector would never be conscious of, yet however, they are “open secrets”.

We have 4 tips for you as follows that your should pay attention to when buying cartoning machines from China

• Cheap Chinese Cartoning Machines Has Nothing to Do with Stainless Steel Construction

A lot of suppliers would claim that they use “heavy duty”, or “full stainless steel” to construct their cartoning machine yet it is not the truth. This is typical with those entry-level cartoning machines with models 100, 120, 150, etc.

This would not definitely be an implication that those companies are lying to you. The probable cause can simply be that they are just trading companies or resellers that have no knowledge of mechanical engineering or know nothing about how the real manufacturer is producing the cartoning machines.

For example, without any exception, all of the 80, 120, or 120 model cartoning machines on the market and made in China are built on AISI A3 Steel and covered with a 1.5 mm thick plate of SUS 304, or even SUS 201. Some would iron galvanized metal as the main structure. All these have nothing to do with the so-called “stainless steel construction”, and in fact, the only SUS used are those thick plates covering the machine.

This is especially to take into consideration if you are requiring a cartoning machine for food application and safe food serving because none of these materials above mentioned are safe FCMs and should not have direct contact with the food materials.

However and admittedly, it is unrealistic and unreasonable to expect a SUS construction cartoning machine at a cheap price of merely USD 20,000 or even USD 15,000. Since the same part or component when made of solid SUS 304 would be 3 times or even 4 times more expensive than if made as coated or galvanized iron.

• Cheap Chinese Cartoning Machine’s Size Changeover is Usually Tedious

Without no exception, all of these mechanical-driven and entry-level cartoning machines like models 80, 100, 120, and 130, etc., are of a complex size changeover process. Even for a trained person, the size changeover can take up to 40 minutes or even 1 hour.

Unlike those high-end packaging machines of multi-axis servos, these cheap cartoning machines are of completely mechanically driven structure that the size changeover involves a lot of manual intervention on those tiny components and adjustment points among the transmission system. Even if some of them are with number indicators, such a size changeover is more experience-based and is not repeatable.

Why you should take care so much of the size changeover time? For a manufacturing company especially in consumer goods, the downtime during the size changeover would stand for the pause in production, which means, the longer the downtime is, the more considerable the loss in production will be.

• Homogeneity — They are Basically all the Same

China s a nation of copy. This is typical in the packaging automation and machinery industry where people copy each other and then beat them with lower prices. The homogeneity in structure and design is typical with packaging machines made in China.

While in terms of electricals, some would claim that they use internationally famous brands, and people without knowledge would be convinced easily. A hidden fact is that, for example. it is unrealistic that you can expect something really awesome at a cheap price.

For example. most of those cheap cartoning machines made in China would use SIEMENS PLC, yet people do not know that the model S7–200 Smart is a very cheap electrical, 30 years old model and not locally supported in a lot of regions.

SIEMENS S7–200 PLC

• Be Careful against being Cheated by Dishonest Suppliers

For some historical reason, buying packaging machines from China will always involve dealing with local resellers.

The reason was that in the early stage where and when China joined WTO there was a lack of talents and professionals who knew the foreign language well or say that those factories could not count on such people on their payroll, they had no choice but could only work with trading companies (Chinese local resellers for export) to sell their machines overseas.

Such a long-lasting reselling culture has grown into an issue, now that with more and more university graduates with competence in speaking and writing English or other languages flocking into the market and factories are now capable of dealing with export on their own, while on the other hand, there are still mountains of trading companies still live on reselling. A result is the lack of transparency and the difficulty in identifying who is the real manufacturer and who is pretending to be the manufacturer.

At the End

There are still a lot of topics to disucss about cartoning machines. If you are company that has decided to automate your packaging process and is looking for cartoning machines, we would like to invite you to discuss with us to find our the right option as well as the right solutions for your cartoning automation needs.