Packing steps and machines for boxes

Packing goods into boxes with case packing equipment begins with a case erector. The case erector forms a box from a flat blank and seals the bottom. The box is then filled, either manually or by machine. A case sealer then closes and tapes the top of the box.

You can opt for semi-automatic machines, where an operator works with the equipment, or automatic machines, which operate independently once set up. FLEX BOX and FLEX TAPE are semi-automatic. AUTOBOX10, AUTOBOX, TOP TAPE, AUTO-TAPE and AUTO&FOLD-5050 are automatic.

The case sealer is responsible for closing and taping the top of each box. Roller conveyors link the machines and move boxes between stations, reducing manual handling. For example, after the case erector forms and seals the bottom, the box is conveyed to the filling area, then to the case sealer, and finally to the palletising station. Each machine is configured for its specific role, ensuring a smooth transition from one stage to the next.

Semi-automatic machines such as FLEX BOX and FLEX TAPE require an operator at each box, so someone is always present to load, hold or guide the box through the process. Automatic machines like AUTOBOX10, AUTOBOX, TOP TAPE, AUTO-TAPE and AUTO&FOLD-5050 run independently once set. The speed of the line is determined by the slowest operation, often the filling. If filling is manual, the output will match the operators’ pace. If automated, the machines can operate at their rated speeds.

Case erector models for boxes

AUTOBOX10 is an automatic case erector capable of 10–15 boxes per minute, up to 720 per hour. It handles boxes 200–500 mm in length, 200–400 mm in width and 150–350 mm in height. It draws flat blanks from its magazine, opens them, folds the bottom flaps and applies tape to the base. This pneumatic machine can store up to 10 carton sizes.

AUTOBOX is an automatic case erector for 16 boxes per minute, equipped with Siemens PLC control. FLEX BOX is a semi-automatic case erector operated in conjunction with an operator.

As AUTOBOX10 is pneumatic, it requires a compressed air supply. It can store up to 10 carton sizes, so if you use several standard sizes, you can recall a saved setting rather than adjusting each time. This reduces changeover time and minimises the risk of incorrect settings.

With any case erector, the blanks must be dry and flat. Damp or warped blanks may not open correctly, which can halt the line or cause jams. Blanks stored in humid conditions may become misshapen, preventing the erector from picking or opening them properly.

Case packing equipment comparison table

The table below shows the main specifications and settings for each case packing equipment model. Compare output rates, carton size ranges, tape widths and features.

To use the comparison table, start by identifying the machine type: case erector or case sealer, and whether it is semi-automatic or automatic. Next, review the output per minute and the range of carton sizes. Then check the tape width each machine supports. For instance, if you require tape 48 mm wide, ensure the model accepts this width. If a model does not list a specific figure, such as output or size range, you can find these details on the product page. This helps you select the right machine for your boxes and production needs.

Case sealer and box taping machine options

FLEX TAPE is a semi-automatic case sealer for tape 48–72 mm, Kraft or BOPP. TOP TAPE and AUTO-TAPE are automatic case sealers for tape 48–72 mm, Kraft or BOPP. AUTO&FOLD-5050 is an automatic box taping machine that folds the top flaps and automatically adjusts to the box’s width and height.

FLEX TAPE is a semi-automatic case sealer, so an operator is present to guide each box through the taping stage. TOP TAPE and AUTO-TAPE are automatic case sealers, which means that once boxes are placed on the infeed, the machines close and tape the tops without further manual handling. All three models accept tape 48–72 mm wide, and you can use either Kraft (paper) or BOPP (plastic) tape, depending on your requirements or shipping process.

The AUTO&FOLD-5050 is an automatic box taping machine that closes the top flaps in a set sequence: front, rear, then sides. It adjusts to the box’s width and height using air cylinders, so it can process mixed carton sizes without manual intervention. Carton length is set via a micro switch. This is especially useful on lines where carton sizes change frequently, as the machine adapts automatically and reduces the risk of taping errors or jams from incorrect settings.

The AUTO&FOLD-5050 is suitable for boxes measuring 200–600 mm in length, 150–500 mm in width and 150–500 mm in height. It operates with tape widths of 48–60 mm, either Kraft or BOPP, and has a belt speed of 16 m/min. The table height can be adjusted from 600 to 850 mm to suit your packing line. It requires a 220 V supply and compressed air. In daily use, keeping spare rolls of tape at the case sealer allows for quick changes, typically taking about a minute. If tape runs out and no spare is available, the line may stop while an operator fetches a new roll.

Roller conveyor options for case packing equipment

The Extend stainless-steel roller conveyor is 550 mm wide and can be set to any length between 1200 and 5000 mm. This flexibility lets you match the conveyor to the distance between machines or workstations. For example, if you rearrange your packing area, you can adjust the conveyor to fit the new setup. Its stainless-steel build is ideal for warehouse and production settings where strength and easy cleaning are needed.

The flexible conveyor is 460 mm wide, with a length adjustable from 1200 to 4800 mm and a height from 600 to 1000 mm. You can extend, shorten or curve it to suit your available space. This is especially helpful if your packing line changes direction or if boxes need to move around obstacles. For instance, on a busy production floor, you might curve the conveyor to move boxes from the sealer to the palletising area, saving space and reducing manual handling.

The powered flex conveyor is available in 4 m or 6 m lengths and moves boxes at 15 m/min. Unlike gravity or push roller conveyors, it transports boxes automatically, so there is no need to tilt the line or push boxes manually. The LOADER UL1790 is designed for loading and unloading lorries, with a belt conveyor 790 cm long and a roller conveyor 1000 cm long, both 80 cm wide. This arrangement reaches into the lorry so boxes can be loaded or unloaded directly, reducing manual lifting and speeding up the process.

Parcel tapes for case sealers

BOPP parcel tape is 48 mm wide and comes in 66 m rolls, available in brown or clear. It is supplied by the box (72 rolls) or by the pallet (3024 rolls). FLEX TAPE, TOP TAPE and AUTO-TAPE use tape 48–72 mm wide, Kraft or BOPP. The AUTO&FOLD-5050 uses tape 48–60 mm, Kraft or BOPP.

BOPP tape is plastic, while Kraft tape is paper-based. FLEX TAPE, TOP TAPE and AUTO-TAPE accept tape widths from 48 to 72 mm, and the AUTO&FOLD-5050 uses tape 48–60 mm. The 48 mm BOPP tape is compatible with all four models, so you can standardise on one tape size if you operate several machines. Using the correct tape width for your case sealer prevents jams and poor seals, which could lead to boxes opening during handling.

Semi-automatic or automatic case packing equipment

A semi-automatic machine such as FLEX BOX or FLEX TAPE requires the operator to work at each box. This arrangement is suitable for lower output and frequent changes in carton size. For example, FLEX BOX is a semi-automatic case erector, and FLEX TAPE is a semi-automatic case sealer for tape 48–72 mm, Kraft or BOPP.

Automatic machines like AUTOBOX10, AUTOBOX, TOP TAPE, AUTO-TAPE and AUTO&FOLD-5050 operate independently once set up. If your case packing equipment line needs a continuous flow of boxes, an automatic model can form or seal each box consistently without an operator at every stage. AUTOBOX10 can process 10–15 boxes per minute.

To decide between the two, calculate how many boxes you pack per hour and consider your busiest times. Compare this figure with the output rates in the comparison table. For instance, if your peak is 600 boxes an hour, a machine rated for 10–15 boxes per minute will keep up. If your output is much lower, a semi-automatic model may be sufficient, especially if you change carton sizes several times a day.

Problems can arise if the machine’s speed does not match the rest of the line. If an automatic sealer is set too fast for the filling step, boxes may accumulate and cause jams. If a semi-automatic machine is too slow, a backlog may develop at the packing station. Choosing a machine that matches your actual and peak output helps the line run smoothly and prevents these issues.

Packing a single carton size or mixed sizes

If you pack one carton size for long runs, a machine set to that size will work through the batch without needing to be reset, so the time spent on adjustment is only needed once.

When packing mixed carton sizes, a machine that adjusts automatically is more efficient. The AUTO&FOLD-5050 changes width and height automatically using air cylinders and sets the box length with a micro switch. The AUTOBOX10 can store up to 10 carton sizes, so a frequently used size can be recalled without resetting from scratch.

To reduce the number of changeovers, group your orders by carton size where possible. For example, if you have several products that fit the same carton, process them together before switching to another size. This keeps the machine on one setting for longer and reduces adjustment time. Each changeover is a chance for errors, such as selecting the wrong size, which can lead to jams or poor sealing.

Factors influencing the price of case packing equipment

The price depends on whether the machine is semi-automatic or automatic, its output per minute, whether it adjusts size automatically, and if it folds the flaps. Tape is the main ongoing cost. The price for each model is shown on its product card.

Tape is supplied by the box or by the pallet, depending on your requirements. If a machine requires compressed air, the cost of running the compressor should be included in your ongoing expenses. Product cards feature a Get offer button for a quote, for example for a sealer with a supply of tape, and an Add to inquiry button to collect several products in one request. This helps you compare options and plan your purchase.

What to check before ordering case packing equipment

Before ordering case packing equipment, check your carton sizes, the number of boxes per hour, and whether you pack a single size or a range. The tape type is important: FLEX TAPE, TOP TAPE and AUTO-TAPE use tape 48–72 mm, Kraft or BOPP, while AUTO&FOLD-5050 uses tape 48–60 mm, Kraft or BOPP.

Before placing an order, list the carton sizes you use and the daily quantity of each. Compare these with the box ranges in the comparison table to ensure your sizes are compatible with the machines. For example, if your largest carton is 500 × 400 × 350 mm, check that it fits within the range for the case erector and sealer you intend to use. This prevents buying a machine that cannot handle your main carton.

Check that you have compressed air available if you plan to use a machine that requires it, such as AUTOBOX10 or AUTO&FOLD-5050. Measure the space for conveyors and plan the flow of boxes from filling to stacking on the pallet. For example, if your packing area is narrow, a flexible conveyor can be curved to fit and connect the machines without blocking walkways.

Once the boxes are stacked on a pallet, plan how to secure them for transport. A pallet wrapping machine or hand film is often used to keep the load stable. This step is vital to prevent boxes from shifting or falling during transit. Planning the full process from carton forming to pallet wrapping helps avoid delays and keeps goods secure.

Questions about case packing equipment

Should I choose semi-automatic or automatic case packing equipment?

Semi-automatic machines such as FLEX BOX and FLEX TAPE require an operator. Automatic machines like AUTOBOX10, AUTOBOX, TOP TAPE, AUTO-TAPE and AUTO&FOLD-5050 operate independently once set.

Which parcel tapes are suitable for the case sealers?

FLEX TAPE, TOP TAPE and AUTO-TAPE use tape 48–72 mm, Kraft or BOPP. AUTO&FOLD-5050 uses tape 48–60 mm, Kraft or BOPP.

Can the machines handle mixed carton sizes?

AUTOBOX10 stores up to 10 carton sizes. AUTO&FOLD-5050 adjusts width and height automatically with air cylinders and sets carton length with a micro switch.

Which machines require compressed air?

The AUTOBOX10 and AUTO&FOLD-5050 require a compressed air supply. For all other machines, please refer to their individual product pages for supply details.