Operation of the LINEBOX-03 packaging line

The LINEBOX-03 packaging line begins with the AUTOBOX10 case erector, which forms 10–15 boxes per minute, up to 720 per hour. Cartons can measure 200–500 mm in length, 200–400 mm in width, and 150–350 mm in height.

Once formed, boxes travel along the RC2M-D powered roller conveyor at 18 m/min to the 1000 mm RC1M passive roller section for manual filling. The RUBBER box taper then seals the cartons using 48–60 mm wide tape, either BOPP or Kraft. The line is PLC controlled and operates on a 220 V, 50 Hz single-phase supply.

The AUTOBOX10 case erector takes a flat cardboard blank from its magazine, opens it, folds the bottom flaps, and applies tape to seal the base. The open box is then placed onto the conveyor, ready for filling. If a blank is damp or warped, the erector may not open it correctly, so always use dry, flat corrugated board. Store blanks off damp floors to keep them in good condition.

The RC1M passive section is where the packer stands to fill each box. The line is designed to wait for the packer to finish, not the other way around. If filling takes longer than forming, boxes will queue here, so adjust the erector’s speed to match the filling staff, or add another packer.

Once filled, the box enters the RUBBER box taper, which folds the top flaps and tapes the box shut. The flap folder is pneumatic, so the taper and the erector both require compressed air as well as the 220 V supply. The line handles one carton size at a time. To change carton size, recall the size on the erector, which can store up to 10 sizes, and adjust the conveyor guides and taper accordingly.

End of line packaging: next steps

A packing line forms part of end of line packaging: everything after production, including boxing, closing, marking, palletising, strapping, and wrapping.

End of line packaging equipment such as these packing lines covers the initial stages: boxing and sealing, or film wrapping.

After closing or wrapping, the next step is usually marking each box with a code or label. This can be done using a thermal inkjet printer for direct printing of dates or batch codes, or a labeling machine for applying printed labels. Both types are available in the shop and can be added after the packing line.

Boxes are then stacked on pallets manually after leaving the line. It is advisable to provide a table or conveyor at the end of the line for closed boxes to accumulate before stacking. With outputs up to 720 boxes per hour, pallet stacking staff must keep pace with the line. Otherwise, boxes may build up and risk being damaged or mixed up.

Once a pallet is full, a pallet wrapping machine or hand film secures the boxes for transport. Strapping is used for heavy boxes to keep the load stable on the pallet. Wrapping and strapping are the final steps before the pallet is moved to storage or dispatch.

Packing line comparison table

The table below lists the machines, output, pack sizes, and supply for both lines; for SHRINKCOMBO, supply details are on its product page.

To use the comparison table, start with your packing method: goods in boxes indicate LINEBOX-03, goods wrapped in shrink film indicate SHRINKCOMBO. The table shows output for each line: boxes per minute for LINEBOX-03 and metres per minute for SHRINKCOMBO. You can also compare the pack sizes each line accommodates.

Carton packing line: sizes, output and tape

The LINEBOX-03 carton packing line is suitable for cartons 200–500 mm long, 200–400 mm wide, and 150–350 mm high. It can form up to 720 boxes per hour using the AUTOBOX10 case erector.

The RUBBER box taper seals cartons with 48–60 mm wide tape, either BOPP or Kraft. Used as a case packing line with manual filling, the LINEBOX-03 forms, transports, and tapes each box identically.

The LINEBOX-03 operates with one carton size at a time, so if you need to pack several sizes in a shift, allow time to adjust the erector, conveyor, and taper settings. At up to 720 boxes per hour, a box is produced roughly every five seconds. Group orders by carton size where possible to minimise changeovers.

Keep spare tape rolls at the taper to ensure a quick changeover. The tape overlap at the front and back of the box can be set from 5 to 50 mm, allowing you to adjust the hold for each box type; longer overlaps provide better flap retention on heavier boxes.

SHRINKCOMBO as an automated packaging line

The SHRINKCOMBO automated packaging line features the A450 automatic side sealer and the V4530 shrink tunnel. The side sealer can handle products up to 150 mm in height, operating at a speed of 15 m/min.

The shrink tunnel processes items up to 1400 × 350 × 200 mm at 10 m/min. This packaging line wraps products in film and then shrinks it tightly around them.

The A450 automatic side sealer encloses each product in folded shrink film, sealing along the side and between each pack. The V4530 shrink tunnel applies heat to shrink the film closely around the product. For instance, a box containing small items can be wrapped and shrunk together as a single unit for display or transport.

The tunnel is the slower machine, so it determines the speed of the entire line, and the sealer’s height limit is the maximum for the line. The standard film is POF shrink film, which is transparent and allows the contents to be seen. This is helpful for products that must be visible to the buyer or checked in the warehouse.

What influences the price of an automatic packing line

The cost of an automatic packing line depends on the number and type of machines included, the output speed, the range of box sizes it can process, and the control system.

Current prices for each packing line are displayed on the product cards above.

The main ongoing costs are the cartons and parcel tapes for LINEBOX-03, or the film for SHRINKCOMBO, as well as electricity and compressed air for the erector and the taper. Wear parts such as tape blades should be kept sharp and clean to prevent stoppages. For example, a blunt blade may leave tape tails or fail to cut the tape, causing jams.

Allow for a length of about 6.1 m for LINEBOX-03, plus space for the packers working at the line. The time required to switch to another carton size is also a factor, especially if you pack many sizes in one day. The product cards above include a Get offer button for a quote, and the Add to inquiry button lets you gather several machines into one request if you are planning a line step by step.

A complete packaging line from individual machines

The three machines in the LINEBOX-03 packing line—the case erector, the roller conveyor, and the box taper (a carton sealer)—are also available separately in the shop.

This means you can start your line with just one machine, such as a carton sealer, and add more packaging line equipment as your needs grow.

If you are beginning with manual packing, start with the step that takes the most time, such as taping or forming boxes. Adding a carton sealer first can save time and reduce strain on staff. Later, you can add a case erector and a conveyor to build up to a full line. Each machine from LINEBOX-03 is designed to work together, so you can add them one at a time as your requirements increase.

Plan the full length of the line, around 6.1 m, even if you only install one machine to begin with. The RC2M-D conveyor connects the machines, and the RC1M passive section provides a place for packers to fill boxes. Planning the total length from the outset makes it easier to expand the line later without moving equipment.

When a packing line is cost-effective

A packing line becomes worthwhile when the same packing task is repeated many times each day: forming, taping, and moving boxes by hand keeps staff occupied who could be doing other work.

The time saved by automating box forming and closing only counts if the filling process keeps up, as the people who fill the boxes are part of the line too.

To assess if a line is cost-effective, calculate the minutes per shift spent forming, taping, and carrying boxes by hand, then multiply by the number of people doing this work. Compare this to a line that can form and tape up to 720 boxes per hour. For example, if three people spend two hours per shift on these tasks, a line could save most of those hours; someone will still need to fill the boxes, load the magazine, and stack the pallets.

A machine tapes every box consistently, reducing the risk of boxes opening during transport. A box that opens in transit may result in a return and extra handling. Manual folding and taping throughout the day can also cause strain on hands and wrists, which a line eliminates. If you pack many carton sizes in small quantities, frequent changeovers can use up the time the line saves, so a single carton sealer or a manual station may be more suitable.

Planning the line: sizes, staff, and space

First, check the largest and smallest box or product the packing line must handle. Boxes outside the range of the LINEBOX-03 will need a second line or a manual station. The hourly output depends on the slowest machine, so if the case erector or shrink tunnel is slower than the others, it sets the pace for the line.

Plan the available space and the direction of flow, allowing room for staff who fill or load, and ensure boxes or film arrive as quickly as the line uses them.

Draw a layout of your workspace, showing where blanks are stored, the side of the erector’s magazine, the filling station, the taper exit, and the stacking area. For example, place the pallet of blanks close to the erector to reduce walking distance, and keep the stacking area near the taper exit for easy palletising.

The working height of LINEBOX-03 is 650 mm; packers stand next to the conveyor, so plan how goods reach the filling area, whether from a pallet, a table, or another conveyor. Ensure there is enough space for packers to work without blocking the line. For example, if two people fill boxes, leave space on both sides of the conveyor so they can move and handle products safely.

Blanks arrive on pallets, so keep one pallet next to the erector. Maintain a walkway along the line and ensure emergency stops are easy to reach. Plan where the pallet of blanks and the pallet of finished boxes are changed, so a pallet truck or forklift can access both without crossing the line. Keep air lines and cables off the floor where people walk.

Tape choices for box lines

The RUBBER box taper on the LINEBOX-03 uses tape between 48 and 60 mm wide. You can use BOPP tape, which is plastic, or Kraft tape, which is paper. Kraft tape can be recycled with the box as paper.

BOPP tape is available with various adhesives. Acrylic tape maintains its hold on boxes stored in cold rooms; hot-melt tape sticks faster to cardboard. Both are applied at room temperature. The RUBBER box taper works with self-adhesive tape, but water-activated gummed paper tape requires a different dispenser. Tape 48 mm wide suits most boxes, while 60 mm tape is better for heavier or larger cartons.

Store tape at room temperature, as cold tape does not adhere well. For example, if tape is kept in an unheated warehouse, it may not stick properly and could cause boxes to open during transport. Before ordering a large quantity of tape, test a few rolls on the line: the tape should unwind smoothly and hold securely on your cartons.

Box or film: what each protects against

A shrink film pack keeps products together and protects them from dust. The SHRINKCOMBO wraps and shrinks film tightly around the product. A box, as used with the LINEBOX-03, protects against impacts and allows stacking for storage or transport. The choice of line depends on how the product is sold and shipped: use film to bundle several items and keep them visible and clean, and a box for stacking and transport.

A box can support weight and be stacked high on a pallet, making it suitable for storage and shipping. Shrink film holds several products together as one unit and keeps them visible. Many packers use both: for example, small items are first wrapped in film for dust protection and then packed into boxes for impact protection and stacking.

Using film requires less material than a box for the same item, but it does not provide protection against impacts or stacking pressure. Cardboard sealed with Kraft tape can be recycled with paper, while film can be recycled with plastics where facilities exist.

Checklist before placing your order

Before placing your order, confirm the dimensions of your boxes or products, the hourly output required, available space and workflow direction, staffing at the packing line, supply of boxes or film, and what follows after the line, such as palletising, pallet strapping or pallet wrapping. The comparison table above details the pack sizes and output rates for both lines.

Begin by listing the carton sizes you need to pack and the daily quantity for each. The LINEBOX-03 accommodates cartons from 200 × 200 × 150 mm up to 500 × 400 × 350 mm, so ensure your sizes are within this range. Compare your required hourly box output with the LINEBOX-03’s capacity of 720 per hour. If you require a higher hourly output, consider installing a second line; for greater daily output, a second shift may be needed.

The line requires single-phase electrical sockets and compressed air, as both the case erector and the taper’s flap folder are pneumatic. Allow approximately 6.1 m in length for the line, plus space for operators and pallets at each end. Ensure you have dry, flat corrugated board blanks, parcel tape for the erector and taper, and shrink film for the SHRINKCOMBO if shrink wrapping is used. Decide who will be responsible for filling the boxes and for keeping the erector’s magazine stocked during operation.

Frequently asked questions about packing lines

What is the hourly box output of the LINEBOX-03 packing line?

The AUTOBOX10 case erector forms 10–15 boxes per minute; the manufacturer rates the line at up to 720 boxes per hour.

What carton size range does the LINEBOX-03 packing line support?

The LINEBOX-03 is suitable for cartons from 200–500 mm in length, 200–400 mm in width, and 150–350 mm in height.

What is the total length of the LINEBOX-03 packing line?

The LINEBOX-03 packing line measures approximately 6.1 m in length and has a working height of 650 mm.

What power supply is required for the LINEBOX-03 packing line?

The LINEBOX-03 packing line operates on a 220 V, 50 Hz single-phase supply. Both the case erector and the box taper require compressed air.