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This piece of machinery is in our packaging category of equipment. A horizontal cartoning machine, also known as an end-load cartoner, takes a blank carton from a magazine, opens it horizontally into carton flights, fills it mechanically, and glues the carton closed.
(Source: https://www.dienst-packsystems.de/en/packaging-systems-products/side-load/folding-box-hk-iv.html)
Topics Include:
- Typical applications
- Use case
- Dimensions and overhead confinement
- Upstream and downstream equipment
- Information needed to choose the correct machine
- Advantages of using this type of cartoner
Typical Applications
These are versatile machines that can fit a number of applications, including:
- Vials
- Bottles
- Pouches
- Tubes
- Blister cartons
- Seal trays
Use Case:
A customer came to SIGMA Equipment looking for a continuous motion glue automatic horizontal cartoner to package their nutrition bar. SIGMA Equipment and SIGMA Integration began the work to set an ADCO 15DBC1DSWD Glue Automatic Horizontal Cartoner to their specifications. As you can see in the video below, the product is loaded and as the boxes are opened and assembled, the product is pushed into the box and the folds of the carton are then placed with glue to seal the box. The machine can now help them box 100 cartons per minute.
Dimensions and Overhead Confinement
Because this machine loads cartons from the side, the dimensions of a box have to be considered.SIGMA always recommends sending samples so we can find the right machine for you. When considering dimensions for your cartons, please refer to the diagram below.
(Source: http://www.allpack.com/StructuresDefined.php)
Overhead confinement compresses the pouch so it fits the width dimension. This helps make loading the product into the case easier and prevents the cartons from being smashed or damaged.
As an example, visualize a cereal box laying on its side. As you can see, the length of the box is where the major flaps are and the width is the minor flaps. The overall depth is the distance between the ends of the carton. These measurements are not always intuitive, but paying attention to these dimensions will save you time and money when you are looking at the specifications for a machine to fit your needs.
Continuous vs Intermittent Motion
When choosing a cartoner you will need to think about what you will need from your machine. There are two types of conveyors that load the product into the carton - continuous motion and intermittent motion. Continuous motion is exactly as it sounds, a conveyor that is constantly moving to load in product between the flights to help move product faster.
Intermittent motion means that it pauses the product temporarily before loading it into the carton. Usually, these machines have a series of chambers that allow the cartons and product to be loaded in 'batches'. The intermittent horizontal cartoning machine is typically best for smaller production lines while the continuous motion machines are used for those who need larger output.
Upstream and Downstream Equipment
Whether you are scaling up, updating a line, or integrating new equipment, you'll want to look at your upstream and downstream equipment that you may need to include or update as well. SIGMA Integration has the capabilities to set up the equipment you need, test it, or integrate it into your production line.
Upstream equipment includes:
- Fillers
- Form, fill, and seal machines
- Multi-head weighers
- Tray sealers
- Cappers
- Accumulation tables
- Metal detectors
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- Checkweighers
Downstream equipment includes:
- Labelers
- Coding equipment
- Case erectors
- Sealers
- Palletizers
- Stretch wrappers
Advantages of a Glue Automatic Horizontal Cartoner
Using a cartoner can help your company leaps and bounds, but in particular, they can help increase efficiency within your packaging process. The cartoner itself requires little human intervention and employees can be redeployed in other production areas to keep staffing costs down, increase output, and keep your production costs down, making your facility more efficient.
These machines can also maintain your package integrity and this leads to higher customer satisfaction and less refunding due to damaged packaging.
However, one of the largest benefits is keeping error rates down. While the machine is not 100% error-free, it does significantly reduce the error rate caused by employees working for long durations. It also decreases repetitive motion injuries for those who were previously handloading.
What to Consider:
Going to a fully automatic horizontal cartoner is a big step in increasing production and hopefully helping you create more revenue and meet your demands. However, before doing so there are a few questions to consider before buying or selling your equipment. They include:
- What are the minimum and maximum carton dimensions?
- What are the minimum and maximum production dimensions?
- What are the bucket sizes of the conveyor?
- Are the buckets fixed or adjustable?
- Is the machine continuous or intermittent motion?
- What options do you need or come with the machine?
- No carton / no pick
- Overhead confinement
- No carton / no load
Conclusion:
Glue automatic horizontal cartoners are a great way to keep production costs down, and increase productivity. With SIGMA Equipment, we can help you find the equipment you are looking for and with SIGMA Integration we can help you integrate and update that machinery to fix your specific needs. Just click the buttons below to get started.
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For any corrugated manufacturer, the top points of concern usually come down to whether all glue joints are being glued properly and whether all boxes produced are accurately square. With those top-two priorities so easy to identify it is no shock that there are a ton of incredibly effective industrial machines designed to deliver exact boxes every time. In fact, it is likely that your manufacturing line rarely produces these types of errors already, but as you know there is almost no acceptance for even a single corrugated box fault. When you work in an industry where a common defect rate target is to have no more than 1 defect for every 3 million boxes produced, there is, in fact, no room for error at all. Just a few issues found in your manufacturer's gap or a couple failed glue laps found in one of your shipments and your operation is in trouble.
As you know, when you ship a trailer full of 2 or 2.5 million good boxes, it is difficult not to be concerned that any customer that finds 2 faulty boxes could mean that they decide to ship the rest of the pallets back to your plant. Then you will have to hire additional labor to re-inspect those pallets of boxes. Such scenarios, are the type of outcome that costs you money, time and customer trust in an incredibly competitive corrugated manufacturing industry. Even if they only have 1 defective box, it still may create troubles requiring you to reassure an angry customer who had a single faulty box cause an equipment jam that cost them thousands of dollars. Avoiding even small corrugated defect issues is important as every failure costs your operations money and customer trust. That is not counting the time you must spend to reassure valuable customers about the quality of your corrugated manufacturing operations. But when the difference between perfection is 0 defects in 3 million, acceptable but not amazing is 1 defect in 3 million, and totally unacceptable is 2 defective boxes out of 3 million corrugated boxes ' what are you supposed to do?
Quality inspection and vision inspection systems can change your corrugated manufacturing reality. With the right quality inspection technology, you will never have to worry about your target defect rates being missed. A quality inspection system can identify every single fault in every single corrugated box that runs through your operational line during high-speed operations. You will never have two defective boxes shipped. Even if your equipment struggles during a run and produces five defective boxes, all five boxes can be identified and ejected before being shipped to any of your customers. No return shipments and no calls with your customers about jams that cost thousands of dollars.
There is a wide range of inspection equipment possibilities. Here are key capabilities that would likely assist your corrugated manufacturing operations:
The product and system improvements available to corrugated box manufacturers through the types of quality inspection and vision inspection systems outlined above are substantial. Individual systems can be purchased for the most pressing concerns of each individual manufacturer and plant. While inspecting proper adhesive placement on each manufacturer's seam and square box-checking would apply to all corrugated operations, print and imagery inspection is more valuable for plants producing the attractive and appealing boxes found at the ends of the grocery store aisles filled with products for sale.
The benefits of inspection systems are the total certainty your manufacturing plant can have regarding the quality of every single corrugated box that leaves your factory. The goal is no longer to have no more than 1 defect for every 3 million boxes produced. The reality is that you should not even have a single defective box in 30 million boxes. Think about what worries you most when a new shipment of corrugated boxes is sent to a customer. Which quality or a vision inspection system(s) could check to make sure that every 1 in a million defect is removed. Inspection systems will give you total confidence in your product, and they can help your bottom line as well. Stop hiring additional labor to re-inspect returned pallets of boxes. Get the right quality and/or visual inspection systems to take your operations to the next level. It will help with your operations, and will probably help you let go of some stress and concern wondering when your next customer will be calling about two faulty boxes.
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Learn about Valco Melton's industry-leading quality and vision inspections systems:
Valco Melton's ClearVision® Camera Inspection Systems offer an all-in-one quality assurance program that guarantees zero-defect boxes. ClearVision® systems include:
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