Case packing machinery packs products into cases or containers and is becoming widely used in the consumer packaged goods (CPG) industry as producers consider practical ways to add automation to their facilities. However, as each line is different and may have ever-changing requirements, no one case packer will suit all applications.
Whether you’re interested in removing manual packing processes or replacing your current case packing system, we explored the various case packing systems to help you better understand what might be best for your business goals.
Of course, as we learn more about your needs, we can recommend a tailored solution that best fits your line, but this should be a good starting point to compare standard case packing solutions and see where the industry is going.
First, we will dig deeper into the five primary case packing machines used for various products and packaging styles and the 4-step process many case packing systems follow. Then, we will touch on the latest advancements in case packing that we’re most excited about.
A case packing machine can be configured to pack products into various case sizes and shapes. The most common type of case is the regular slotted container, but many other options are available, such as trays, cartons, and bags. Five case packing machines are commonly used for secondary packaging operations, depending on the product, application, and facility layout.
Two-Axis Gantry Style Case Packers: Able to pack both flat and vertical packs on the same system. Easy to program new recipes and very user-friendly. Able to pick up much heavier products than your more sophisticated delta style robots. Product must be presented to the packer in an oriented fashion. Tends to come with a lower cost and smaller footprint (less linear floor space than larger robotic lines).
Gravity: Very simple compact system. Packs product flat or laying down in the case only. Ideal for bags of IQF poultry beef and seafood, frozen fruits and vegetables, and other refrigerated and frozen flexible packages. Offered in stainless steel washdown for high caustic washdown environments.
Case Packing with Vision-Guided Delta-Style Robotics: Product can be presented to the packer in a random un-oriented fashion. Robots pick on the fly and eliminate traditional collation systems that you see with gantry-style case packers. Allows for much faster speeds and very few change parts. Great for a number of applications, including high-speed carton loading, variety packs, and more. Able to feed from bulk or WIP by integrating a bulk feeding system.
Wrap-Around Case Packing: Wrap around cases or trays are designed to pack products into die cut packaging, which forms directly around the product. The wrap around case offers a tight case loading, using less material per case as well as giving more strength for palletizing and distribution. Reduces corrugate use when compared to a standard regular slotted case. Provides you with an all-in-one erect/load/seal system.
If you’re interested in learning more about case packing styles and machines, we took a deep dive into case packer types here.
Below video features various types of systems.
Generally, packing products into cases with a case packing machine can be broken down into four steps, which we explore in the example below. Your process may differ depending on the packaging style and desired machine. Still, the process will help determine which case packing solution and customizations are required to meet your secondary packaging goals.
The first step in the process is case formulation. Typically, the case erector forms flat cardboard into a three-sided box. The box's bottom is sealed with glue or tape.
Products are fed into the packing station by an infeed conveyor.
The packing head picks up products and places them into the case. Depending on the machine's configuration, the products may be packed in single or multiple layers. Once the case is full, it's sent to the case sealer.
The case sealer seals the case's top, bottom, or both ends. The sealed case is discharged from the machine and ready to be shipped.
The packaging industry is constantly moving forward through advancements in technology and practices to meet the needs of consumers. Case packing machinery is one way producers are improving how they pack and ship products to support their strategic objectives.
Before case packing machinery, producers had to rely on manual labor to load products into boxes or containers. That took a lot of time and frequently led to mistakes. The pandemic further exacerbated challenging labor conditions, requiring technology interventions to fill productivity gaps and ensure companies could meet increased consumer demand.
Today, with sophisticated robotics, like vision-guided systems, and other technology advancements, producers can implement various tools and features to optimize their operations. Here are some advantages of using case packing machinery that are revolutionizing the industry.
Case-packing machinery can pack products much faster than manual labor, so businesses can get their products out the door quicker. Versatility is a priority for many CPGs. Automated case packing systems can run multiple products and a variety of secondary containers on the same system with minimal to no manual changeover.
It can reduce errors and improve accuracy, leading to fewer product returns and happier customers.
One of the most significant costs for companies is labor. Case packing machinery can help companies save money on labor costs while increasing efficiency. Remember, automated machines can run 24/7 with very little human involvement. Long-term savings can be substantial despite the possibly higher initial cost.
When products are packed manually, there's always the risk of injuries. Case-packing machinery minimizes this risk, keeping employees safe.
When workers feel safer, and their responsibilities are more aligned with their skills, recruitment and retention rates soar. By utilizing automation, companies can train and offer their workers more high-demand roles where they can further advance their careers. This should help boost morale and facilitate stronger professional bonds and loyalty.
Businesses can often change their packaging processes more easily with case packing machinery. For example, if a company wants to change the size of the box they're using, they can make a few adjustments to the machinery instead of starting from scratch.
The machinery can help businesses reduce their environmental impact. Ask your secondary packaging partner what steps they are taking, such as more efficient air systems, fewer pneumatic components, and more servo and eco-friendly vacuum technology. Keep in mind some case packers help reduce waste and minimize corrugate like the wrap around case packer.
The equipment can be scaled to accommodate the needs of expanding businesses. In many cases, companies won't have to invest in new equipment whenever their packaging needs to change.
Case-packing equipment can reduce quality control issues and assist companies in guaranteeing that their goods arrive in excellent condition, resulting in loyal clients and glowing testimonials.
As more companies seek these solutions, case packing machinery will continue to evolve and thrill business owners. Robotics, customizations, user-friendly interfaces, advanced materials, and enhanced safety features are some of the most exciting developments that will continue to shape the industry and help producers move forward to better serve consumers.
The packaging industry's future is automation, and case packing machinery is leading the way. Case packing machinery will evolve and become even more sophisticated, making the packaging process faster, easier, and more efficient.
Businesses adopting case packing machinery will stay ahead of the competition and keep costs down. So, if you're in the packaging business, invest in case packing machinery—it's the industry's future.
We offer the latest machinery and technology to help businesses automate secondary packaging. Contact us today to learn more about how we can help you take your packaging operations to the next level.
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