Case erectors come in different types, and may also differ in terms of specifications. This makes it important to know what different case erectors are used for and how to make the best choice for your packaging requirements. Case erectors can be broadly divided into two categories:
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1. The standard machine, which has one magazine with a specific case range. With these case erectors, alternating different case sizes that fall within that range can be formed.
2. The modular case erector, which can be assembled with different configurations and add-ons according to specific requirements. With this packaging machine, multiple magazines can also be used if necessary, which allow different case sizes to be erected interchangeably with little-to-no operator involvement.
Both case erectors differ in terms of specifications, namely:
The number of cases the packaging machine can form in 1 minute
The minimum and maximum size options of the case
The closure of the bottom of the case (i.e., tape or hot melt)
The amount of cases that fit in the magazine;
The position of the flat magazine;
Communication capabilities with other machines;
Options for custom settings and sizes
The type of case erector and what specifications are needed depends on the purposes for which it is used. There are a number of guidelines for choosing case erectors, with respect to industry and business type.
Small manufacturing businesses and warehouses
Automating processes is often the main objective of small manufacturing businesses and warehouses. Choose a basic machine when the case erector is not part of a packaging line and when it is not necessary to form different box sizes interchangeably. When a product requires a visual or manual inspection before being placed in the box, it makes sense to opt for a dedicated packaging machine that balances automation and manpower. In this case, boxes are pulled and formed on demand, filled by an operator and then closed automatically.
E-commerce companies
Reducing volume is probably the most important objective of e-commerce companies. As a result, they work with a wide range of case sizes. A modular machine with multiple magazines is best suited for this purpose. The correct case size can be called based on the size of the products, and for this purpose the machine can be integrated into the packaging line.
Manufacturing and production companies
The case erector is likely to be part of a larger packaging line at manufacturing and production companies. In this case, a modular machine is the best choice because it can communicate with other machines in the line. In the case of multiple packaging lines that are close together, an in-line machine with the magazine at the end can be a good solution because it allows packaging lines to be placed closer together.
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Welcome to this article, which is an in-depth guide to carton erector machine, If you’re looking for any information about a carton erector machine, you will find it right here. So keep reading to learn more.
A carton erector machine is also known as a carton-forming machine for automatic or semi-automatic carton machines. Its main function is to erect (unfold) the cardboard box and seal the bottom flap so that it is ready for packaging.
There are semi-automatic and fully automatic carton erector machines. Using a semi-automatic carton machine requires the operator to manually position the box and remove it from the erector machine after the process is complete.
However, using a fully automatic carton erector machine is another matter. Fully automatic erector machines do not require manual operation. It feeds the cardboard boxes from the magazine into the installer and automatically positions the cartons, increasing the efficiency of the packaging process.
The working principle of this erector machine usually changes according to its actual mode of operation. As a rule, there are semi-automatic units and automatic units, and the principle of their operation is relatively similar, slightly different.
Nevertheless, the overall design of the device has unique features that allow your packaging line to run seamlessly. This is a typical unpacking erector machine engineering;
At this stage, the cartons are loaded onto square tracks for easy alignment and feeding. The erector machine has a horizontally stacked – square tool changer for easy correct alignment of boxes. Once stacked, they are automatically indexed into place and provide a stable and continuous feed of cartons.
Here, the appropriate boxes need to be fed into the erector machine. Therefore, the floating gripper is triggered to adjust accordingly to adapt to changes in the situation. First of all, the upper feed box runs warped and the marked housing runs smoothly.
The double floating fixture then lifts the carton from the top of the stack to ensure reliable feeding, regardless of whether the carton feed is uneven due to corrugation.
The lower and upper suction cups trigger a positive opening of the shell. Therefore, the housing is sealed from the bottom by a vacuum gripper, while the mechanical opening arm is lowered to hold and push away firmly.
Our company provides reliable housing formation even on boxes where the manufacturer has too much adhesive for joint joints, which prevents opening.
The overhead clamp is activated to open the lid to smoothly close the slight flap. This design allows enough space for the small flaps to fold inward and eliminates the common paper jams encountered during flap closing. This typically occurs when running cartons with misaligned scores.
During transmission, the square housing of the stepper beam facilitates an error-free erector with tape or adhesive. Technically, the better the carton goes into the sealed part, the better it comes out. Therefore, you need to strictly control the carton throughout the process to get a high-quality box, regardless of the potential challenges. Mainly, this is the basic working principle of an ordinary carton packer.
Depending on different factors, they are available in several types. Common products you can find in the market include the following;
As the name suggests, this is a carton packer that offers a limit speed of up to 50 cartons per minute. It has a production-proven design with quality specifications for peak production on the packaging line.
Regarded as a workhorse erector machine, it has a heavy-duty steel frame structure powered by a powerful motor drive.
It is a small carton unpacking erector machine, which is suitable for erecting and forming small boxes common in daily life, such as plug end boxes and snap locks/1-2-3 bottom boxes.
There is also a carton erector machine called a small carton erector machine, which is very common in industrial scenarios and is very suitable for erecting and forming large corrugated cardboard boxes. Our company is relatively versatile, so it can be used for different packaging applications in various industries.
It is an automated, end-of-line packaging solution that solves ergonomic problems when employees are dealing with repetitive tasks. The unit includes an interactive color touchscreen for the operator to use in manual mode and quickly change the housing size being installed.
It also comes with additional housing connections and hot melt adhesive seals for the automatic selection of carton sizes.
In addition, it has high-speed bottom erector capability, and servo adjustable side straps increase speed.
This type of carton erector machine folds the two small bottom flaps into a CDSE blank, then applies glue to the two small flaps and folds it over the main flap.
The build box is kept for a period of time to ensure that the glue dries and hardens to provide a strong seal. It is very efficient because it ensures fewer changes – and therefore saves time during production runs. The device can use either cold melt adhesive or hot melt adhesive.
It can handle boxes of various sizes but requires some operator involvement to make the boxes move around the erector machine.
In general, it is fast and somewhat accurate, so it is ideal for small and medium-sized productions. Operator involvement is required at any unpacking stage. Basically, this erector machine is designed so that it automatically forms, folds, and seals the underside of corrugated boxes. It has an ergonomic, easy-to-access magazine with a retainer that ensures a clean release of each blank from the magazine.
In addition, it has a flap folder and a pusher that holds the pusher during the transition to a carton erector machine with a bottom taper. This variant has a side belt drive that can form a bottom-sealed box at different speeds of up to 15 cartons per minute.
Designed with the strongest frame components, it is ideal for demanding 3-shift setups and is easy to integrate into existing production lines. The carton erector machine with a bottom taper unit lowers the flat box blank to standing vertically in the trail-in easy-to-load carton. Its secondary flap folds using a pneumatic mechanism, while the primary flap does a pneumatic mechanism, while the main flaps are folded using a rotary actuator.
It offers enclosure mount and bottom erector capabilities to guarantee optimal durability, reliability, and value. The unit is designed with a sturdy frame that is ideal for the most demanding 3-shift environments.
Sales and cranks. In addition, it comes with a walk-box that loads the box into the device while running.
It has a box installation capacity of up to 30 cartons per minute with a low-level magazine for loading and unpacking without lifting. The unique step-and-beam enclosure moves the square enclosure from opening to erector. In addition, it has a unique square housing of mandrel during the erector process, and mainly uses adhesives to seal the housing. It guarantees the reliable performance of the machine at a low cost.
The motor is eliminated in the change in the carton of different sizes. It saves the box size recipe in HMI and triggers automatic box repositioning when selected. The operator needed to load new carton box blanks, and the unit quickly returned to forming and erector. It is suitable for businesses that are struggling with high turnover or those companies that employ unskilled employees.
And by using this type of carton erector, your company will dramatically increase productivity. The unit features a positive vacuum-box opening, a walk-in power box magazine, and lug-driven box transport, which can form and seal up to 20 cartons per minute. It features a single-piece welded tubular steel frame assembly and a heavy-duty drive assembly. The system features safety interlocking guards and an intuitive operator interface for easy and safe device operation. You can complete the conversion of the various bin sizes in 5 minutes.
Some common industries that use this particular erector machine are:
A great variety of food and drinks package need to use by this carton erector machine to help place products into the carton boxes.
Of course, this is a very important industry, as it is guaranteed high speed and accuracy, which is paramount in terms of obtaining the desired market results.
Various car manufacturers and assembly plants are often using carton erector machines for building cartons to prepare to pack their products, and this is an essential piece of equipment. Industrial self-uniformity, speed, and accuracy are very basic issues.
The carton erector machine comes in handy for a pharmaceutical product manufacturing company since it came into being, they are used for effective packaging of such items.
Usually, the erector machine forms different shell sizes, suitable for packaging various pharmaceutical products, such as tablets, capsules, vials, ampoules, etc.
Different products for personal care and hygiene are also often packaged in boxes erected by the device. Such products require uniformity and accuracy, so such equipment is required to guarantee the best results. Confectionery product packaging many candies are often produced in large quantities, so packaging is a required mechanism to ensure efficiency and consistency. The carton opener is fast, and accurate and can form different cartons for the packaging of various confectionery products.
The main function of the carton erecting erector machine is to convert the box blank into a fully erect bottom-sealed box.
However, it also has other accessibility features in the packaging settings, such as the following：
Increase packing speed to ensure you have the right inventory and delivery to your customers.
Easy to operate, reducing the need for manual labor
Deliver faster, more consistent performance
Make sure all boxes are square before the erector
Designed with opposite cup effects
Easy integration into existing packaging lines
State-of-the-art photoelectric induction control system
Used to form and seal cartons of the same size
Designed with cutting-edge erectors machine safety system
Sturdy steel construction
Equipped with high-quality parts
Stable performance and long life
This carton erector machine consists of various parts designed to perform different functions. However, it is always essential to know some noteworthy parts of this erector machine to improve operational efficiency and performance
The housing is sealed. Common parts of an erector machine worth knowing include:
They help to turn off and on different control circuits within the erector machine.
It consists of various drums and belts, mainly used to transport cartons from one station to another within the equipment.
This part introduces the carton into the erector machine for follow-up, forming, forming, and installation.
It is a safety-measuring key designed EC2 that protects the erector machine from dangerous events by disconnecting the circuit and cutting off the power supply.
This is a housing that houses multiple electrical components for the operation of the carton ready to be erected.
It lubricates all contact parts of the erector machine to reduce friction and ultimately improve the service life and efficiency of parts and erector machines.
The assembly consists of different units designed to minimize and protect equipment and operators from potential damage or injury during the enclosure formation process.
Trigger it to ensure that the flap of the carton folds appropriately and accurately according to the size.
This is a small programmable motor that operates the robot component of the carton erector machine. Typically, it drives the precision and repeatability of the device by receiving feedback about the positioning of components and directing their movement and positioning.
It applies erector tape to the bottom of the carton to ensure that it is firmly fixed to secure the product safely.
They are used as fixtures within the erector machine, usually holding and assisting in carton movement.
Using a carton erector machine can actually bring a lot of convenience to product packaging. It can also increase packaging productivity. The carton erector machine automatically creates square corners. The sturdy corners of the box are essential for palletizing and transporting products. These provide a solid basis for weight distribution. Besides, there are also many advantages of a carton erector machine.
The carton erector machine can convert boxes faster than manual work. Human workers can assemble an average of three boxes per minute. An employee might build boxes in a typical day, working 84-hour shifts without break. The erector machine assembles boxes in the same 8-hour shift, or even the fastest carton opener can produce cartons per minute.
This erector machine requires little to no need to handle corrugated board blanks when forming boxes. Technically, it opens, squares, and seals the bottom of the carton; Therefore, you need the operator to load the blank and enter the dimensions of the erector machine to do the rest.
Standing boxes can easily lead to boxes that are not square in shape, which seem weaker when stacked on pieces of paper. However, square boxes can withstand heavier weights, making them less susceptible to damage by transport. This is feasible when using a carton erector machine, which guarantees that the product arrives intact.
Modern carton erector machines are designed to allow them to convert in minutes. Therefore, it can reduce downtime when you need to supply multiple boxes of different sizes for a specific production line.
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Erecting cartons manually is labor-intensive because workers must assemble a sufficient supply of construction cartons. Erecting cartons with human forces increases production time and takes up considerable floor space. Instead, the carton erector machine can form boxes as needed and only needs a limited space, which frees up floor space for other operations.
A carton erector machine will save your production and workers’ wages. It can also efficiently produce erect cartons.
The price of a carton erector machine ranges from hundreds of dollars to tens of hundreds of dollars, which involves many factors. Since different customers have different customization requirements, the price of small carton erector machines varies greatly.
The customer’s customized requirements mainly include the following aspects:
Support a wider range of carton sizes
Replace PLC, inverter, touch screen, motor, etc. with more well-known brands
Add some extra features
It is not strange that the price of a carton erector machine may vary. Since different customers may have different expectations and special requirements. It is necessary to figure out what are your priority needs so as to find a suitable product for your company. Here we offer you several influencing factors.
Product quality itself is the basic factor that determines the price. Including the value of various accessories, whether the life of the accessories and the use method are perfect, the technical content, and the quality of the product determine the price of the erector machine.
On the market, if the product is more popular and the demand is strong, which will affect the price of the carton erector machine to a certain extent, and this factor will be reduced due to sufficient market supply.
Similarly, during the peak season of the year, the price of this erector machine will be higher, and this market-oriented price fluctuation will not have a substantial impact on the price. However, businesses can also choose a reasonable time to avoid this unnecessary passivity when purchasing a carton erector machine.
All products on the market have their own marketing strategy, some of which are not perceived by everyone but are reflected in the price.
With the continuous progress of society, people’s sense of service has gradually been cultivated. Now no matter what product you buy, if there is no good after-sales service system, then your product will lose half.
Therefore, when consumers choose a carton erector machine, they prefer to spend more money and go to those companies with good after-sales service to buy carton erector machines. Because if the erector machines have problems in the future, it is also a good guarantee to find sales to solve them in the future.
Notable maintenance practices for a carton erector machine include the following:
Develop a detailed upgrade plan for the carton erector machine to ensure it meets the appropriate application and design requests.
Remove the chips or dirt in the machine once a week.
Once a month, clean and lubricate the upper skateboard, the middle knife, and the front top knife mentioned in the previous section.
Replenish the oil in the wheel box once every two years.
It must be noted that several parts cannot be refueled: a send-back with rollers.
Every time you refuel, do not add too much, so as not to cause the failure of the microswitch due to immersion in oil.
Always be vigilant when doing it manually.
The operator must understand the machine’s function.
Know the strength of the carton erector machine and do not put an excessive burden on the machine.
It is always good to follow the instruction manual that came with the machine.
Generally, we guarantee after-sales service to customers in the form of technical support, returns, and compensation.
support
Technicians provide customers with technical guidance services such as project consultation and fault diagnosis in the form of service hotlines, whether they are located in the city or remotely, they can achieve immediate response and achieve customer satisfaction.
On-site support
When support does not solve the problem, or direct on-site service is required according to customer requirements, the company will assign experienced professional technicians to provide on-site service.
When the problem cannot be solved by or on-site support, the customer has no special request and returns to the company’s nearest repair point for repair.
If the erector machine is damaged in transit and the customer does not want to wait for another new erector machine, we will provide you with the same amount as the erector machine. This only applies if the erector machine is damaged during transport due to an accident that cannot be prevented.
Are you planning to get a new case erector for your company? There are some fundamental case erector requirements that you need to consider.
The first thing to look at is the preferences of your company. The second determinant is your downstream packaging process. The good news is that you can clearly define all these requirements.
There are so many case erector manufacturers who deal in different types of products. Thus, you will not fail to get one that perfectly meets your needs. The essential requirements when choosing a case erector include:
Case type
Speed
Seal type
Duration
In this article, we will be looking at each of them to help you make the right decision. However, it is good to start by understanding what case erectors are. Read on to gain more insights on how to choose the right carton erector.
A case erector is a case-forming machine that automatically forms, folds, and seals corrugated boxes from flat cartons. With these systems, operators will not stop packaging products because they need to build cartons.
The packaging machines come in automatic and semi-automatic formats. Case erectors can create six to twenty cases per minute.
It is effortless to integrate a case erector into the current packaging line of your company. You can pair erectors with case sealers to get a complete forming, filling, and sealing packaging solution.
You can still add a case erector to a packaging line even if you only produce 500 cases per day. Let’s have a look at the main types of case sealers in the market.
Automatic case erectors automatically form, fold, and seal the bottom of the corrugated cases. These are machines that don’t need the input of an operator. When you pair an automatic case erector with the case sealer, you will get a complete packaging solution for your company.
A semi-automatic case erector handles various carton sizes. These machines require the involvement of an operator to move cases through the machine. Case erectors work hand in hand with case sealers to enhance the efficiency of case packaging. Here is a guide on how to choose the right carton erector.
The specifications, styles, and materials of corrugated cases are sneaky complex. However, most people underestimate their role in the packaging process. These elements can make an entire line unfunctional.
It can force you to spend a lot of money on troubleshooting the problem. You can avoid this problem by having some up-front information.
In this post, we will not cover the nitty-gritty of corrugated containerboards. We will only look at the three specific elements to help you choose the most appropriate case erector.
Top on the list is the case type that you run on your production line. Most manufacturers design their erectors to handle RSCs (Regular Slotted Cases). Therefore, those who run RSCs have so many case erector manufacturers at their disposal.
However, if you run a more exotic case type, Half-Slotted Container (HSC) or Full-Overlap Slotted (FOL), you will have fewer case-forming brands.
The next consideration is the dimension of your case(s). You have to look at the width (across the machine) and length (direction of travel) of the cartons. Most carton erector manufacturers accommodate a broad range of dimensions.
However, most of what you get in the market is defined by the maximum and minimum dimensions. If your boxes start to approach either end of that pocket, you will have to evaluate the box forming machine models more carefully.
If any of the case dimensions go below 6 or 7 inches; you deal with the small end carton erectors. The large end typically starts from around 16 to 17 inches. If the case dimensions begin to flirt towards one end of the spectrum; you will need to pay close attention to the range of case erector sizes that you review.
The third thing to look at is the corrugated quality that you are using. The corrugated quality affects the performance of the case erector. Therefore, you need to understand the quality of your case material to help you choose the right carton erector.
With these facts, you need to take a close look at the specifications of your containerboard. Check the extent to which the containerboard manufacturer complies with these specs. Also, get to understand what will happen to the specs when you subject the containerboard to your factory-driven, local, and regional environmental conditions.
With this in mind, make sure you get an erector design that will handle what you are using. For instance, a flimsy, thin, and often crushed corrugated may open well with an opposing cut design. However, it will struggle to erect or open when using a dome or pin system.
There are so many examples where carton erectors can fail. To sum it up, you need to evaluate the corrugated material quality. Make sure you choose a case former that can erect a case manufactured from the corrugated material of your choice.
It is not hard to understand this point. Choose a carton erector that either matches or exceeds your downstream packaging operations speed.
It is not hard to answer this question. However, the response you get here disqualifies particular case-forming manufacturers. There are two simple observations that we can use to explain this;
It is possible to make a carton erector run slower. However, making the machine run faster is an impossibility.
Machine designs that support fast case erecting speeds are more expensive than those that have slow speeds. Therefore, the fast case erectors are generally overpriced for mid and low-speed applications.
The technology and design of a carton erector that handles 5 cases per minute are very different from those designed to erect 50 cases per minute. High speeds call for more robust and precise designs. The technology and design features that these machines use are also more advanced.
Thus, case erectors that have fast speeds can work down-market efficiently. However, you cannot take a slow, entry-level erector and ramp it up-market for higher speeds.
The high-speed carton erector manufacturers also find it hard to remain price competitive at lower speeds. It can force them to change the makeup and design of their machine. Technology supports higher speeds, but you have to pay for it as a customer.
How does all this affect the case erector that you choose? For higher speeds, you will have a smaller pool of case erector manufacturers at your disposal.
The type of seal does not narrow the field of carton erector manufacturers in any way. Most manufacturers of case erectors deal with particular versions of glue-seal erectors and tape seal erectors. Even though most factories prefer the seal-type, you need to be aware of specific operational and cost considerations.
In most cases, glue carton erectors are 20 to 30 percent more costly than tape erectors of the same speed. If you are dealing with a mid-range machine, you may pay up to 10 to 20 thousand dollars more.
Glue nozzles and hoses get clogged easily, which calls for regular maintenance.
The glue erector overspray can be pretty problematic. You cannot seal along an entire length of flap without accepting a certain level of overspray. It can get messy over time.
According to most experts, a large portion of the premium paid for the glue erectors is offset by the operational efficiencies absent in the tape sealing system.
Tape rolling systems run out of tape much faster than the speed at which the glue tanks get empty. Attending to your production line more frequently comes with certain operational costs. It is a common scenario when the tape runs out.
The tape quality impacts the tape system in a big way. If you buy cheap tape, the extra line stoppages will make you pay for the same.
The reliability of tape systems is lower at fast speeds. This point narrows down to simple chemistry and physics. With fast speeds, it becomes harder to keep up with the case-taping sequence.
Choosing the number of case erectors that will seal cases is just one of the decisions that you have to make. There is no clear wrong or right choice for the carton erector. It typically depends on your preferences and what makes sense to your production line.
This point refers to the asset life. How long would you like this machine to run your business operations? Like speed, the duration will also remove certain case erector manufacturers from your list. To get a machine that will meet your desired asset life, you may be forced to pay more than you thought.
In this article, we don’t suggest a specific case erector model or brand. There are so many things to put into consideration for you to buy the right carton erector. The choice typically depends on your budget, individual preference, and packaging needs.
The key considerations include the case type, carton erector speed, seal type, and asset lifetime. Doing in-depth market research will help you to make the right decision. It is good to go for a machine that will add a lot of value to your business operations.
Have you ever thought about some of the ways that you could find some hidden cost savings potential in packaging? Ten years ago, it wasn't a high priority. However, as transportation and warehousing costs have continued to steadily rise, companies realized that packaging offered a fresh opportunity to cut costs.
Despite that new found awareness, many companies are still struggling to identify where exactly they can cut costs in their packaging without creating bigger problems down the line. A good place to start, say some experts, is with small incremental changes that can add up to big results. Here are a few to consider.
1. Cut the size of your primary packaging. Sometimes, a small change to the product's primary packaging (what the consumer takes off the shelf) can result in a big reduction in overall supply chain costs. For example, a food company redesigned their packaging for frozen pizza so that the box's length and height were reduced by 1/16th of an inch and 3/8th of an inch, respectively. It was almost imperceptible to the consumer, but that small decrease allowed the company to use a different size case, which in turn allowed it to utilize the pallet better and fit more boxes of pizzas into a case. These changes ultimately resulted in transportation cost savings of over $500,000 per year.
2. Change the count. Sometimes you don't even need to change the size of the packaging; you just need to reconfigure it so you can fit more product inside. A health and beauty company saved a quarter of a million dollars by changing the package to allow products to nest inside it differently, which reduced the package profile. The new package also resulted in a smaller case, which saved materials and drove cube efficiencies, creating a 50% increase in product density, so there was more on a pallet. And when you increase product density like this, it can create a kind of ripple effect, gaining efficiencies in warehousing and storage and in transportation, while reducing handling and labor.
3. Alter the size of the shipping case. Making small adjustments to the secondary packaging (the box or case in which the product is shipped) can also produce big savings. For example, by slightly altering the size of a case of product and how it was unitized on the pallet, one major retailer was able to add an extra layer of product on the pallet. That extra layer allowed them to get more product into each truckload shipment, cutting down on the number of shipments of inbound product by several hundred over the course of a year.
4. Leave a gap. And sometimes the changes to the shipping case don't even have to affect the box's overall size. Walking through the DC one day, one manager began to wonder whether he could use less material to create the shipping cases for cereal boxes. At the time, the company was shipping its cereal boxes in a "full-coverage" regular slotted carton created by gluing the flaps together. Could they get away with cutting the size of the flaps by an inch? The box would now have a gap in the middle, but it would still be able to safely transport cereal boxes. That simple change saved about 20% on the shipping case material required, which netted a little over a million dollars in material savings in a year, and all they did was adjust the glue nozzles on the case erector, moving them by a mere inch.
5. "Rightsize" your carton lineup—which may mean more, not fewer, options. Sometimes, companies try to save money by limiting the number of shipping boxes and cases they use. While that can save money on material costs, but it often turns out to be a case of "saving nickels by spending quarters." Many times, this effort to reduce complexity means that the company is shipping products in boxes that are too large. To keep the product from rattling around in the box and becoming damaged, the company often has to pay more for filler material, and the product takes up more room in the warehouse and on the truck than is strictly necessary. Sometimes something like increasing the number of boxes available from, say, nine to 12 has ended up saving a company around half a million dollars a year.
6. Buy better-quality corrugate. While using a better corrugated box for your secondary shipping packaging might raise your corrugate costs, using a sturdier box might end up saving you money overall. First off, a better-quality corrugated box can provide better protection to the product, which reduces damage. Second, with a stronger box, you can stack more cases on top of one another, and thus, get more cases on a pallet. This allows you to save money on storage and transportation.
BUT DON'T GO TOO FAR! As you make these tweaks to your packaging, be careful not to go too far. Keep in mind that the primary purpose of packaging is to ensure the product arrives at its destination undamaged. The quarter of an inch that you shave off here or the extra product you squeeze in there should not lead to a higher incidence of product damage.
How do you avoid making that mistake? You need to test it to make sure it will work in a distribution environment. Test the packaging at both the case and unitized-pallet load level to see how it handles compression, shock, and vibration. Drop tests, for example, will indicate how well your packaging can prevent product damage.
Think about how all of the packaging components (the box, the pouch, the case, the pallet, the shrink wrap) will work together as a total delivery system. It's not about minimizing the costs of the individual components; it's about optimizing the overall system.
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