Choosing a Case Erector? Here’s the First of Five Steps.

Published June 1,

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In this five-part series, we’ll walk you through the considerations you should make when evaluating or purchasing a case erector.

There are a few fundamental case erecting requirements to consider first. These are the requirements that only you can define. They are dictated by your downstream packaging processes and your company’s preferences.

Because the case erecting segment is made up of dozens of companies producing hundreds of case erector variations, these essential decisions are an important first step because they immediately narrow your scope and reduce the number of case erecting manufacturers you have to consider.

The essentials require you to ask:

Which case?

Which speed?

Which seal type?

Which duration?

We’ll take these one by one…

Which case?

Corrugated case materials, styles, and specifications are a sneaky-complicated and sometimes underappreciated part of packaging. That is, until they force you to shut down a line and spend resources you didn’t budget for troubleshooting a problem that could have been avoided with a bit more up-front information.

While we won’t get into the nitty-gritty of corrugated containerboard in this particular post, we will touch on three particular aspects that should impact your evaluation of a particular case erector or case erector manufacturer.

First, what case type are you running on your line? Almost all case erector manufacturers design their equipment to handle Regular Slotted Cases (RSCs). So if you run RSCs, you’ll have plenty of case erector brands to choose from. But if you run an FOL (Full-Overlap Slotted) or an HSC (Half-Slotted Container) or a more exotic case type, you’ll find that your choice of case forming manufacturers will dwindle quite quickly.

Second, what are the dimensions of your case or cases? Similar to case type, you’ll find that most manufacturers will operate in a fairly wide pocket defined by minimum and maximum dimensions for length (direction of travel), width (across machine) and depth (aka height). However, you’ll want to look more carefully at box forming machine models if your case dimensions begin approaching either end of that pocket.

The small end usually comes into focus when any of your three case dimensions dip below 6 or 7 inches. The large end of the pocket usually begins somewhere around 16 or 17 inches. Either way, if your case dimensions begin flirting with one end of the spectrum you’ll want to pay close attention to the case size range of each case erector you review.

Third, what type of corrugated quality are you using? While we could (and probably will) write several articles covering the quality of your case material, we won’t go into too much detail here. Instead, we’ll simply state the following: corrugated quality can, and will, impact your case erector’s performance.

With these facts firmly in mind, it behooves you to look closely at your containerboard’s specs, how well your containerboard manufacturer adheres to those specs, and what happens to those specs when the containerboard is subjected to your regional, local, and factory-driven environmental conditions. Then, after you’ve taken a closer look, you’ll want to line up an erector design that can handle what you’ll be using. Why? As an example, thin, flimsy or often crushed (not the technical terms) corrugated may open fine with an opposing cup design, but struggle to open or erect when using a pin and dome system. There are too many such examples to entertain here. Suffice it to say, you MUST evaluate the quality of your corrugated material and make sure your case former of choice is up to the task of erecting a case that’s made of your chosen corrugated material.

Which speed?

This is pretty straight-forward. Your case erector needs to match or exceed the pace of your downstream packaging operations. While it’s a simple question to ask, the answer to this question automatically rules certain case forming manufacturers in, and others out.

The reason for this can be boiled down into two simple observations:

1 – You can make a fast case erector run slower, but you can’t make a slow case erector run faster.

2 – Machine designs that enable fast case erecting speeds cost much more than case erectors designed to run at slower speeds. As a result, fast case erectors are usually overpriced for low- and mid-speed applications.

In general, the design and technology of a case erector required to run 5 cases per minute is quite different than one tasked with erecting 45 cases per minute. Higher speeds require more precise, robust designs and often utilize advanced design features or technology. So while case erector suppliers with fast machines can easily work down-market with their product portfolio, it is harder for erector manufacturers to take a slow, entry-level erector and ramp it up-market, to higher speeds.

Still, without dramatically changing the design or makeup of their machine, those high-speed erector manufacturers will often find it difficult to be price competitive at lower speeds. In other words, technology enables speed but you usually have to pay for it. (There is a caveat to this that we’ll discuss in the last installment of the series.)

So what does all of this have to do with buying a case erector? Put simply, zeroing in on speed forces you to zero in on a smaller pool of potential case erector vendors.

Which seal-type?

Seal-type does not narrow your field of erector manufacturers at all. Most case erector manufacturers sell both tape-seal erectors and some version of a glue-seal erector. While it’s true that seal-type is mostly a factory preference, there are some cost and operational considerations to be aware of.

In favor of tape

→ Glue erectors are often 20-30% more expensive than a similar speed tape erector. For a mid-range machine, this can mean ten to 20 thousand dollars.

→ Glue hoses and nozzles get clogged and require regular maintenance.

→ Glue overspray can be problematic. Sealing along the entire length of a flap often means accepting a certain amount of overspray. This can get messy.

In favor of glue

→ Most experts would argue that at least a portion of the premium you pay for a glue erector is offset by operational efficiencies that are not present in a tape-seal system.

→ Tape rolls run out of tape faster than glue tanks get emptied, so there’s an operational cost associated with having to tend to your line more frequently when tape runs out.

→ We’ve found that tape systems are heavily impacted by tape quality. You can buy cheap tape, but you’ll pay for it with extra line stoppages.

→ Tape systems are less reliable at fast speeds. This usually comes down to simple physics and chemistry. The faster you go, the more difficult it becomes for the taping sequence to keep up.

At the end of the day, choosing how your case erector will seal cases is just one more decision for you to make. There’s no clear right or wrong, only preference and what makes sense for your line.

Which duration?

Really, what we’re talking about here is asset life. How long do you want this investment to last in your operation? Much like the speed consideration, duration will weed out some case erector suppliers. However, in this case, it is a little easier to find yourself paying more than you should for a machine that appears to meet your asset life needs.

We’re not saying there’s a right or a wrong answer, here. There are perfectly reasonable arguments to be made for buying and owning an entry-level case erector with a short asset life. But you should be mindful of your preference and clear-headed in your assessment of asset life for each product and each case erector manufacturer.

Key factors for choosing case erector machines in packaging lines

In today’s industrial age, where every second counts, automation is the cornerstone for accelerating operations, increasing accuracy and maximizing profits.

Within this context, a key piece in the production line is the automatic carton erector. A strategic solution that can work in conjunction with fillers, sealers and labeling equipment, thus optimizing the final product packaging process.

Case erectors are advanced solutions that quickly fold and assemble cartons. However, choosing the right equipment is a strategic decision that requires considering multiple factors, defining the company’s needs and analyzing the various options on the market.

In this post we identify the key factors for selecting a cash forming machine that meets operational requirements and contributes to the optimization of industrial results.

Types of case erectors: automatic or semi-automatic?

The design specifications of carton erectors may differ from one manufacturer to another. But generally speaking, these machines fall into two categories:

Automatic

The automatic carton erector performs the entire carton assembly process without human intervention. The same machine takes the flat carton from the magazine, assembles it into the proper shape and folds its bottom flaps.

Some automatic case erectors include modules that complement the packaging automation, such as case sealing modules (with adhesive tape or gluing). In this case, the case erector itself folds and seals the bottom flaps, ejecting the assembled case, ready for product insertion.

These are efficient machines perfect for high-demand operating environments. Depending on the manufacturer, automatic case erectors can erect up to 13 cases per minute. In addition to increasing overall productivity, they are solutions that decrease labor requirements and increase worker safety.

If you are looking for more details, kindly visit Carton Erector.

Semiautomatic

These case erectors automatically perform only part of the case erecting process. They require operator intervention at the beginning of the process, to manually load and position the flat boxes in the system. The erector then assembles the case, closing the bottom flaps. In addition, it holds it firmly while it is being filled by an operator.

At the end, the operator must manually close the top flaps and press the switch that allows the box to slide into the sealing station.

Semi-automatic case erectors represent a first step towards full automation of the packaging process. They can be an option for small companies or warehouses that still have manual processes and wish to use independent machinery.

Key factors for choosing the most suitable automatic case erector

Selecting an automatic carton erector, with the most suitable design specifications, depends on the expected production results, packaging line characteristics, carton sizes, packaging customization, etc. Some of the key factors are as follows:

1 Type of industry or business

The nature and objectives of the company define the type of case erector. For example:

In manufacturing or production companies it is usual to need a case erector that is part of a larger packaging line. In addition, at the industrial level, the use of machines that guarantee production stability is required. In this case, the best option is an automatic case erector that can be integrated with other equipment on the line and that automatically adjusts to the different case dimensions, avoiding downtime.

For e-commerce companies or warehouses that handle various case sizes, the most productive option is also an automatic case erector that integrates with the packaging line, increases the speed of operations and automatically adapts to the size of the case.

2 Flexibility

It is vital to consider the adaptability of the automatic case erector. These machines must be easy to use and simple to adjust to different packaging needs, case types and other specific needs of the production process. For example, an automatic carton erector with a flexible configuration should:

Present a tactile interface, with simple control panels.

Adapt to special box formats.

Automatically adjust to different box sizes.

Incorporate the option of closing/sealing and pressing/gluing modules. This reduces downtime and ensures a smooth workflow with seamless transitions. In addition, staff can devote their time to more productive tasks.

3 Case erector speed

The speed of the erector to erect the cases directly affects the operational efficiency. It is therefore essential to evaluate the packaging process and define how fast the end-of-line should run and how many cases should be erected per minute.

Of course, when choosing a high-speed automatic case erector, you always have the option to operate at a slower speed, but you may also be choosing and paying for features and speed that your company does not need. However, it is also possible that you are choosing and paying for features and speed that your company does not need. What would be the ideal choice?

It is important to consider a formers with a certain expansion capacity, which can operate 10-15% faster than the packaging line operates. This is a percentage that serves as a baseline for any unforeseen production issues or line optimization in the future.

4 Eco-efficiency

Adopting state-of-the-art machines can guarantee both high precision of operations and high energy efficiency. In addition to this, it is important that the automatic carton erector has the capacity to work with both new and used cartons.

For example, there are automatic case erectors that allow the reuse of cartons from suppliers as packaging for outgoing products. This not only reduces costs by reducing box purchases, but also reduces waste and the cost of disposal.

This feature saves costs for the company and helps to reduce the environmental impact of the industrial and logistics sector.

5 Need for customization

There is a wide range of forming machines on the market, making it relatively easy to choose a standard model that works with a given size and style of box. There are even advanced solutions that automatically detect the size of the box and adjust their system.

But if the process or carton type specifications are outside of what a standard carton erector can offer, custom engineering is the only option. A custom-designed automatic case erector is the best way to optimize packaging operations.

It is a machine that will possess the advanced features needed to raise industry productivity, lower maintenance costs and adapt to expected eco-efficiency requirements.

Tecnimusa: advanced automation solutions that increase industrial productivity As an engineering company, we reaffirm our commitment to excellence and innovation.

We design and manufacture automated solutions that optimize production lines and promote environmental sustainability.

Our vision is always focused on the future. We have a team of expert engineers who work continuously to help our customers overcome the challenges of the textile industry, improve intralogistics processes and be part of an industrial revolution that respects the planet.

An example of this is our automatic carton erector, which erects up to 800 cartons/hour and can work with used or new cartons. If you are ready to transform your logistics operation, contact us.

At Tecnimusa we chart the path to intelligent and environmentally friendly automation. We design customized solutions aligned with your company’s objectives.

CE-12 Box Erector Machine

For a reliable, compact carton erector, the CE-12 is a smart choice. This vertical carton erector is easy to operate and maintain and is designed for high-volume, fast-paced industrial use when efficiency is essential. Streamline the boxing process and cut labor costs while increasing production speed. The machine will grip flat corrugated boxes from a magazine rack, open the collapsed form into a box, and apply pressure-sensitive tape to the bottom of each carton too form uniform and secure bottom seal. Presenting an open box that is ready to be filled by an operator. The complete process requires minimal human involvement.

It is constructed from quality parts with an innovative design and provides reliable, problem-free operation Compatible with a wide variety of carton dimensions using both RSC and HSC case types. A compact design and small footprint is ideal as a self-standing operation, or integrated to a conveyor line.

The CE-12 features a High-capacity magazine infeed with a capacity of up to 100 cartons and No-Box-in-Rack and Fault visual/auditory signal for reminding operators when they need to replenish the cartons. + The easy to use, intuitive menu-based operation panel features a step-by-step motion activation and tool-less adjustment that allows box configuration changes to be made in a few minutes with minimal training.

Parts Adopted

Siemens PLC

AC Contactor :SCHNEIDER

Bearing : NSK

Sensor: LEUZE

Wayne Automation

Businesses that depend on reliable packaging to get products to their customers can benefit from prioritizing their end-of-line processes. If erecting cases manually plays a big part in your business operations and you’re struggling to keep up with demand, then investing in an automatic case erector makes sense.

Wayne Automation offers several case erectors based on your packaging needs and required speeds. The kind of case erector you need will depend on:

Which case sizes and styles your company uses

The case orientation (right- or left-hand)

Your speed requirements

Our professional team is here to help you decide on the right case erector or carton erector for your particular needs based on your current and anticipated demand.

The company is the world’s best Carton Packing Machine supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.