Automated Packaging Lines

Packaging Line Components

Key Benefits & ROI

• Labor Reduction: Automated systems reduce manual packaging labor by 60-80%
• Throughput Increase: 2-5x faster than manual packaging operations
• Consistency: Eliminate variability in pack patterns, sealing quality, and labeling
• Product Protection: Gentle handling reduces product damage and waste
• Footprint Optimization: Vertical integration maximizes space utilization
• Flexibility: Quick changeovers support multiple product SKUs

Case Erector Technology

Automated case erectors form corrugated cases from flat blanks, dramatically reducing manual labor and ensuring consistent case quality for downstream equipment.

Erector Types

• Random Case Erectors: Handle multiple case sizes without changeover, ideal for high-SKU operations
• Uniform Case Erectors: Single case size, higher speeds up to 25 CPM
• Wraparound Case Formers: Form cases around product loads, minimal material usage
• Side-Load Erectors: Cases formed perpendicular to product flow for compact layouts

Sealing Options

• Tape Sealing: Pressure-sensitive tape, lower operating cost
• Hot-Melt Glue: Stronger seal, tamper-evident closure
• Combination Systems: Tape sides with glue on bottom flaps

Case Packing Solutions

Case packers load products into erected cases with precise placement, orientation, and count control. System selection depends on product type, case configuration, and throughput requirements.

Robotic Case Packing

• Flexibility: Handle multiple product types and case configurations
• Quick Changeover: Recipe-based programming for fast SKU changes
• Gentle Handling: Vision-guided placement prevents product damage
• High Speeds: Delta robots achieve 100-200 picks per minute
• Space Efficiency: Compact footprint vs. traditional packers

Traditional Packers

• Top-Load Packers: Vertical case loading for stable products
• Side-Load Packers: Horizontal loading for laydown applications
• Drop Packers: Gravity-fed systems for bulk products
• Partition Inserters: Automatic divider placement for glass and bottles

Shrink Wrapping Systems

Shrink wrap packaging provides product protection, tamper evidence, and multi-pack bundling. Modern systems offer precise temperature control and film savings.

Shrink Wrapper Configurations

• L-Bar Sealers: Manual or semi-automatic, up to 20 packs/min
• Automatic Side Sealers: High-speed continuous motion, 60-120 packs/min
• Sleeve Wrappers: Open ends, minimal film usage
• Full Overlap: Complete enclosure for maximum protection

Heat Tunnel Technology

• Variable Speed: Adjust dwell time for different film types
• Zone Control: Independent temperature zones optimize shrinking
• Energy Efficiency: Insulated chambers and recirculation reduce energy costs
• Film Compatibility: PVC, polyolefin, and bio-based films

Labeling & Printing Integration

Automated labeling and printing systems apply product identification, shipping labels, and variable data with precision and speed.

Label Application Methods

• Top Labeling: Overhead applicators for horizontal surfaces
• Side Labeling: Tamp or wipe-on application for vertical surfaces
• Wrap Labeling: Full or partial wrap around containers
• Print & Apply: Thermal printers with automatic label application

Variable Data Printing

• Lot Codes: Date/time stamps, batch tracking
• Barcodes: UPC, Code 128, GS1-128, QR codes
• Serialization: Unique identifiers for track-and-trace
• Database Integration: ERP/WMS connectivity for real-time data

Palletizing Technology

Automated palletizers stack finished cases into optimized pallet patterns, eliminating manual lifting and increasing warehouse-ready output.

Robotic Palletizers

• Articulated Robots: 4-6 axis robots for complex patterns and mixed SKUs
• Layer Palletizers: Form complete layers offline, rapid pallet building
• Collaborative Robots: Safe operation alongside workers without guarding
• Multi-Line Systems: Single robot services multiple production lines

Conventional Palletizers

• Inline Palletizers: Single-file case infeed, lower cost entry point
• High-Level Palletizers: Elevated layer formation, high-speed operation (200+ CPM)
• Low-Level Palletizers: Floor-level operation, easier maintenance access
• Gantry Palletizers: XYZ motion systems for ultimate flexibility

Stretch Wrapping Systems

Stretch wrapping is the final step before palletized loads ship, securing products to the pallet for safe transportation and storage. We provide a full range of stretch wrapping equipment from semi-automatic stand-alone units to fully automatic conveyorized systems integrated into your production line.

Stretch Wrapper Types

• Turntable Wrappers: Pallet rotates on a powered turntable while the film carriage applies stretch film. Semi-automatic models wrap up to 40 loads per hour. Ideal for lower volume or warehouse applications.
• Rotary Arm Wrappers: Film carriage rotates around a stationary load, eliminating the need to rotate the pallet. Best for unstable, heavy, or very light loads that cannot spin.
• Ring Wrappers: High-speed ring design for automated inline wrapping at production line speeds. Fully conveyorized with automatic cut and clamp.
• Orbital Wrappers: Wrap product through a rotating ring for horizontal bundling of long products like lumber, pipes, profiles, and doors.
• Straddle Wrappers: Conveyorized wrapper with a straddle design that lifts the pallet load during wrapping for full bottom coverage.

Load Containment Technology

Modern stretch wrappers use engineered pre-stretch technology to reduce film consumption by up to 50% while maintaining or improving load containment force. Programmable wrap patterns with adjustable top/bottom wraps, overlap percentage, and containment force targets ensure consistent, secure loads every time. Integration with pallet conveyors, labelers, and shipping systems creates a seamless end-of-line workflow.

Complete Line Integration

Packaging lines require seamless integration of all components with synchronized control and optimized product flow.

System Integration Services

• Layout Design: CAD modeling and material flow simulation
• Controls Integration: Single PLC architecture or distributed control
• HMI Development: Unified operator interface across all equipment
• Network Communication: Ethernet/IP, ProfiNet, OPC-UA protocols
• Line Synchronization: Coordinated speeds prevent bottlenecks

Conveyor System Design

Packaging line conveyors must balance speed, accumulation, and equipment interfaces while minimizing product damage and maximizing uptime.

Packaging Conveyor Requirements

• Speed Matching: Variable speeds coordinate with equipment cycles
• Zero-Pressure Accumulation: Buffer between equipment stages
• Product Spacing: Precision gap control for equipment infeed
• Reject Handling: Divert defective products to rework stations
• Changeover Flexibility: Tool-free adjustments for different product sizes

Quality Control Integration

Modern packaging lines incorporate inline quality inspection to identify defects before products reach customers.

Inspection Systems

• Vision Inspection: Camera systems verify fill levels, cap presence, label position
• Checkweighers: Verify package weight within tolerances
• Metal Detection: Inline conveyor-mounted and gravity-fed metal detectors identify ferrous, non-ferrous, and stainless steel contaminants with automatic reject systems. Essential for food safety, pharmaceutical compliance, and consumer product quality
• X-Ray Inspection: Detect foreign objects and verify piece count
• Barcode Verification: Confirm scannable labels and correct data

Controls & HMI Systems

Advanced control systems provide centralized monitoring, data collection, and remote diagnostics for packaging line optimization.

Control Features

• Recipe Management: Store settings for multiple products and case sizes
• OEE Tracking: Overall Equipment Effectiveness monitoring
• Alarm Management: Prioritized alerts with troubleshooting guidance
• Remote Access: VPN connectivity for off-site support
• Data Logging: Production counts, downtime analysis, maintenance tracking

Changeover Optimization

Quick changeover capability is critical for facilities running multiple SKUs. Modern packaging equipment minimizes changeover time and complexity.

Changeover Strategies

• Tool-Free Adjustments: Hand-wheel and quick-release mechanisms
• Recipe Storage: Automated recall of equipment settings
• Color-Coded Components: Visual guides for part placement
• Modular Tooling: Cassette-style quick-change systems
• Single Minute Exchange of Dies (SMED): Lean manufacturing principles applied to changeovers

Maintenance & Support

Packaging line reliability depends on comprehensive maintenance programs and rapid response to unplanned downtime.

Maintenance Programs

• Preventive Maintenance: Scheduled service based on run hours or calendar
• Predictive Maintenance: Vibration analysis, thermal imaging, oil analysis
• Spare Parts Programs: Critical parts inventory on-site or on-call
• Remote Monitoring: 24/7 system health monitoring with alerts
• Annual Audits: Comprehensive system assessment and optimization recommendations

Safety & Compliance

Packaging equipment must meet rigorous safety standards to protect operators while maintaining productivity.

Safety Systems

• Safety Guarding: Fixed guards, interlocked gates, light curtains
• Emergency Stops: Strategically placed E-stop buttons with category 0 shutdown
• Lockout/Tagout: Energy isolation for maintenance activities
• Safety PLCs: Redundant safety logic separate from control systems
• Risk Assessment: OSHA and ANSI compliance documentation

ROI & Payback Analysis

Packaging automation delivers measurable return on investment through labor savings, increased throughput, and improved quality.

Financial Benefits

• Labor Cost Reduction: Eliminate 3-10 manual packaging positions
• Throughput Increase: 2-5x improvement over manual operations
• Quality Improvement: Reduce product damage and rework by 50-90%
• Space Optimization: Vertical integration frees floor space for production
• Typical Payback: 18-36 months depending on volume and labor rates

Why Choose EHS for Packaging Lines?

With over 30 years of material handling and automation experience, we provide complete packaging line solutions from initial concept through installation and long-term support. Our systems integration approach ensures all equipment works together seamlessly for maximum productivity and reliability.

Complete packaging line solutions include: process analysis and throughput modeling, equipment selection and sourcing, layout design and simulation, controls integration and programming, installation and commissioning, operator training, spare parts programs, and ongoing maintenance support for years of reliable operation.

Frequently Paired Solutions

Complete packaging systems require upstream product delivery and downstream shipping preparation:

Industries We Serve