Automatic Cartoning Machine has drastically changed the packaging way of finished products all over the industry.

Additionally, packaging demand for products in majorly the food and pharmaceutical industries has greatly been met with improved efficiency.

Furthermore, the need for improved efficiency and productivity has been brought about by the benefits that come with an Automatic Cartoning Machine. They include:

Time Saving

Production lines that operate under very high speeds tend to waste a lot of time during packaging due to backlog.

This is different with the Automatic Cartoning Machine because it guarantees a dependable and continuous cartoning output.

Because machines are not prone to fatigue unlike human labor, the production process can go on for hours on end.

When unnecessary breaks are eliminated, the output is usually high with great efficiency.

Safety

Operating an Automatic Cartoning Machine is very safe compared to manual packing of products.

Automation has ensured that risks such as pinching of hands have been eradicated for safe production.

Improved Quality

The packing quality of the product is greatly enhanced and the box cannot be easily damaged. Manual carton packing involves the risk of damaging the carton appearance but Automatic Cartoning Machine follows a definite packing procedure.

Automation

The control panel of an Automatic Cartoning Machine has an intelligent display panel that operates using PLC.

This facilitates easy monitoring and trouble shooting in the event of a breakdown.

There are various types of Automatic Cartoning Machine available in the market. The main types include:

Intermittent Mode

This is an Automatic Cartoner Machine whose method of operation involves an intermittent motion.

Such machines are normally of a lower intermediate or intermediate speed with their cost very pocket-friendly.

Intermittent Automatic Cartoning Machine are usually ideal for cartons of very big sizes with stability being a major advantage.

Since it handles large boxes with their containment area being big, operating it on very fast speeds is literally impossible.

intermittent mode

Continuous Mode

This type of Automatic Cartoning Machine contains several barrel cam loaders that are used to insert the boxes.

Their motion is horizontal to facilitate the forward motion of the boxes insertion and their backward movement.

Their design is configured in such a way that maximum speeds can be achieved in their operations.

Additionally, the price is relatively higher compared to intermittent cartoning machines with their design being more complex.

continuous mode

Vertical Automatic Cartoning Machine

The operating mechanism of this type of Automatic Cartoning Machine involves the loading side of the erected box facing up.

Also, the front and rear panels are made to be horizontally positioned.

This type of machine is recommended for products that do not require vertical loading into their packaging.

vertical automatic cartoning machine

Such products may avoid vertical loading to evade production flaws like abrasion on their surface in the process of loading.

You can learn more about vertical cartoner machine.

Horizontal Automatic Cartoning Machine

This type of machine is highly recommended for cartoning products having regular shapes like medicine or biscuits.

Products are fed automatically and carton flaps closed with batch numbers printed and sealing done with hot melt glue.

horizontal automatic cartoning machine

You can also learn more about horizontal cartoner machine.

Top-Load Cartoning Machine

This type of Automatic Cartoning Machine resembles the vertical cartoning machine in the manner in which the boxes are fed into the system.

However, instead of a single unit, it contains a combination of machines integrated into it including components like carton closers, robotic loaders and tray formers.

top load cartoning machine

Here is more information about top loading mechanism.

The main parts of an Automatic Cartoning Machine are as follows:

PLC Control Panel:

This is the cartoning machines Human-Machine Interface (HMI) and is fully automated.

It is used to control and observe processes such as carton placement, product per carton and their placement.

All process parameters are set here with the option of the machine stopping in the event of a failure.

Automatic Lubrication System:

The Automatic Cartoning Machine is an electromechanical device with very many movable parts.

To ensure the lifespan is increased, all these parts must be regularly lubricated.

Sufficient lubrication is automatically provided to components such as conveyors, bearings and gears.

Guide Rails, Carton Chute and Conveyors

The Guide rails function is majorly creating a pathway for the conveying of the cartons.

An electric motor runs the conveyor that carry the cartons from one point to the next and is inclusive of rollers.

The carton chute ensures that once products are packed in the carton, it passes through it for further packaging.

Besides, this will be in bigger boxes for easy transportation and storage.

Inkjet Spraying Mechanism

An Inkjet printer comes with the Automatic Cartoning Machine and is used for labeling purposes on the carton.

Details such as the products expiry date, manufacture date and any other indications are printed for the consumer’s knowledge.

Carton Feeding Mechanism

This is a pneumatic system that uses vacuum to suck blank cartons in preparation for the cartoning process.

The cartons are contained in the carton storage room with can be adjusted to accommodate different carton sizes.

Leaflet Feeding System

This mechanism ensures that leaflets are fed into the cartoning process by placing them on cartons via pins.

The products then proceed to the conveyor belt for the next process.

Electric System

The Automatic Cartoning Machine gets its operating power from its electric system including powering the pneumatic system.

It is composed of the electric panel combined with electric motors providing the gearing system.

There are various types of Automatic Cartoning Machine in the market but all their working principle is basically the same.

Generally, blanks of cartons are erected and the product is automatically inserted into the carton and then sealed.

Automatic Cartoning Machine can be utilized individually and product loaded or they can be integrated to an upstream system where products are introduced.

An example is an automatic Cartoning Machine connected to a tray-sealer that seals trays with a film and placed into cartons by the machine.

automatic cartoning machine

Based on the type of machine, cartons are pushed into the machine using different types of inserters.

A continuous cartoning machine contains several pushers with a cam barrel that continuously pushes them individually until products are inserted.

Intermittent Cartoning Machines have just one inserter that is either mechanically driven or has a servo-motor to drive it.

The Cartoner then discharges the loaded cartons after they have been inserted and secured in a collated style.

The cartons then pass through a several guides that assist in folding the tuck end of the carton. Also, the tuck and dust flaps are then folded and tucked by the tuck folder and flap folder respectively.

Immediately the cartons have been sealed by the machine, they are ejected from the cartoning system. They are then taken to a downstream packaging system such as a case packer or an overwrapper that completes the packing process.

Some very important features of an Automatic Cartoning Machine include:

i. Guaranteed Safety: when products don’t conform the preset parameters, an alarm is raised and operation suspended for rectification.

Pressure and vacuum are also well protected to automatically ensure effective and quality cartoning.

ii. Automatic Diagnosis: the cost of maintenance is greatly reduced when faults are diagnosed in advance and rectified.

The machine automatically indicates faults and ceases to operate to avoid further damage.

iii. Operational Synchronization: the Automatic Cartoning Machine has product and carton continuously fed with all other functions working simultaneously.

All these operations occur with high stability and are very reliable.

iv. Operational Convenience: adjustments can easily be made depending on the size of the product being cartoned.

Speed is controlled via variable frequencies with PLC and HMI devices easy to operate.

Some of the limitations of using an Intermittent Mode Automatic Cartoning Machine include:

a) Acquiring the machine is quite expensive especially in the early operations after purchase and when installing it.

b) It has a very slow mode of operation compared to other types of Automatic Cartoning Machine therefore reducing output.

Automatic Cartoning Machine have operational challenges like:

a) Poor carton quality can lead to difficulties in packaging due to continuous stoppages.

b) In the event of a system error occurring, wrong diagnosis and debugging can reduce the production quality.

c) The cost of spare parts for the complex machinery is usually high with most parts not being interchangeable.

d) The complex nature of the Automatic Cartoning Machines makes its maintenance very costly and tedious.

In terms of operation, the feeding system of a semi-automatic Cartoning Machine is not automated therefore its operations are not simplified.

This tends to reduce the overall output of the machine and the production speed.

For efficient production and considerable output, many operators have to be employed to make up for lack of automation.

Some designs of the Semi-Automatic Cartoning Machine may also be sophisticated enough to allow inclusion of accessories such as box conveyors and carton magazines.

Some of the benefits of a semi-automatic Cartoning Machine include the reduced cost of maintenance. It can also be easily used with other safety devices like the Human Machine Interface (HMI) that safeguards the unit’s integrity.

semi-automatic cartoning machine

A fully automatic Cartoning Machine is very intricate and requires very little physical human input for its operations.

It is considered one of the most efficient cartoning machines that can carry out all the cartoning machine operations.

The fully automatic Cartoning Machine has the ability to verify the quality of the packaging carton being used.

This ensures that the correct quality carton material is utilized.

Some of the accessories that come with the fully automatic Cartoning Machine include folding systems and ink jet printers.

They can also insert brochures in the packaging and apply a system of hot melt glue used fir sealing.

All the operations carried out on the fully automatic Cartoning Machine are controlled from a central point using a computer.

This control unit is responsible for regulating, controlling and managing the operations with minimal labor required.

When sourcing for an Automatic Cartoning Machine, the results it can yield and the operational comfort greatly influence the decision.

Some of the vital factors to consider include:

 Size

The Automatic Cartoning Machine should be economical in the space that it will occupy in the final premise.

Also, the design should be made as slender as possible but without compromising any of its performance capabilities.

Flexibility

Due to the high capital input cost of acquiring an Automatic Cartoning Machine, its flexibility should be diverse.

The design should be aligned in such a way that it is adjustable enough to package various box designs.

It must also be able to be easily configured into a variety of packaging lines and work well after installation.

Level of Output

An Automatic Cartoning Machines efficiency plays a role in influencing the number of products it can package in a day.

The product manufacturer should be consulted widely regarding the maximum output of the Cartoning Machine.

Safety Precautions

Due to the nature of their operation and complexity of design, operators of Automatic Cartoning Machine are exposed to many risks.

Any operational mistake can prove to be fatally costly and severely catastrophic.

Emergency precautions such as a shut-down function that is automatically emergent combined with a shut-down manual button are recommended.

This together with other auxiliary precautions should be factored in during design.

Automation

Based on the end-user’s level of demand for automation, the manufacturer makes an informed decision to avail the most appropriate machine.

In the event of a system error, the Automatic Cartoning Machine must have a trouble-shooting system.

This ensures that the machine ceases operation immediately to evade further damage and to allow for rectification.

Project Budget

The cartoning process should be clearly understood for the firm to arrive at the correct budget estimates.

Some considerations include the efficiency of the product being packaged, how the ergonomics is improved together with package aesthetics.

The current or initial cartoning process should be clearly analyzed together with future improvements of the process.

Some improvements to consider include making the cartons tamper proof or reducing the labor involved to bare minimum.

 Machine Serviceability

A machine that requires a very limited change of parts in between carton adjustment changes is mostly recommended.

The cartoning machine should be able to seamlessly have changeovers when different cartons are applied.

Picking Mechanism

The picking method of the Automatic Cartoning Machine should be fully compatible with the product being packed.

For the entire cartoning process to run flawlessly, the blanks need to be correctly picked by the machine.

The Automatic Cartoning Machine has many industry applications including:

Pharmaceutical Industry

Products in the pharmaceutical industry such as ointments, oral liquids and others are packaged using an Automatic Cartoning Machine.

Its major gain in the pharmaceutical industry is preventing counterfeiting by having the cartons safely sealed.

Food Industry

Packaging food in cartons assists in the prevention of dust and microbial pollution while preserving its quality.

This also eases the foods transportations, circulation and its storage extended.

Cosmetics and Commodities

Cosmetics and other commodities can be easily packed using either vertical or horizontal Automatic Cartoning Machine.

They include products like facial cream, cosmetic cotton, soaps and toothpaste with abnormal products removed by the PLC.

Electrical Appliances And Hardware

The best option for packaging electrical appliances and related hardware is the vertical Automatic Cartoning Machine.

Such appliances may include devices like chargers, power sockets, electric bulbs and bearings.

Safety concerns in the Automatic Cartoning Machine have been addressed in the following ways:

a) Sensors: a variety of sensors using multi-pulse technology are used in the designed and linked to the control program.

When they detect an error or empty carton, the machine is automatically stopped by the safety controller.

b) Automatic Sealing: burns and cuts experienced by operators in manual Cartoning Machines have been eliminated by automatic sealing.

c) Critical Motion Control: there is a coordinated motion control in the decentralized drives with product variance controlled by automated adjustments.

d) Programmable Logic Control (PLC): it provides a fail-safe for all the processes with worker’s safety guaranteed by automatic diagnostic error stoppages.

e) Light Curtains: these are optoelectronic sensors capable of detecting something within proximity of an area.

They bring the Automatic Cartoning Machine to a stop when a worker accidentally comes into contact with them.

In the process of utilizing an Automatic Cartoning Machine, many challenges may be experienced.

Some of the problems encountered in the operations and their possible solutions include:

a) The vacuum suction may be poorly positioned. This requires a total refit of the whole vacuum system and calibrating it to the right position for efficient cartoning.

b) The infeed of the carton magazine may sometimes draw a flat blank into the machine.

This can be rectified by using multi-pulse equipment such as a photoelectric sensor that warns and stops the machine in the event of a malfunction.

c) Sometimes the carton blanks cannot be automatically separated when the machine is picking them.

This requires an entire shutdown of the machine and physically separating the blanks while swapping them with operational ones.

d) When the Automatic Cartoning Machine temporarily runs on the manual mode, it tends to have reduced operational speed.

The immediate solution is to alter the design of the drugging board adaptable to adjusting the machines speed.

e) On selected occasions, the carton store room can sometimes be improperly adjusted.

This calls for immediate adjustment of the carton store room to ensure seamless delivery of the cartons.

f) When the Automatic Cartoning Machine continuously operates at very high speeds, it becomes physically unstable.

Servo Motors and other servo stabilizing techniques can be applied to smoothen the operations of the machine.

g) The sucker tubing can sometimes have some leakage or get blocked thus leading to a malfunction of picking cartons.

The sucker tubing with a leakage should be replaced immediately after being unblocked with a new one.

Based on the working technique of the Automatic Cartoning Machine, black cartons are sucked using the pneumatic system from their stack.

Powering the pneumatic system before machine operation since the air will be used in the suction system.

The advantages of using a Continuous Mode Automatic Cartoning Machine are:

i. It is fully automated enabling all process and control parameters to be set and observed from a single point.

ii. The carton packing has a very high output because the machine operates at very high speeds.

iii. The packaging procedure is easily executed due to the progressive nature of the chain.

iv. The cost of production is significantly reduced due to the handling provisions that are very little or sometimes non-existent.

v. The carton efficiency is greatly improved due to the accuracy of the procedure.

vi. A lot of production time is saved due to the machines high speed compared to other machines.

For all your cartoning machine needs, contact us now.