How a carton erector fits into your packing line

A carton erector takes a flat blank and forms it into an open carton with a closed bottom. The front and rear bottom flaps are folded first, then the two side flaps. This prepares the carton for filling.

AUTOBOX and AUTOBOX10 tape the bottom after folding the flaps. FLEX BOX only folds and holds the bottom flaps, and the case sealer tapes both the top and bottom after filling. The carton erector is positioned at the start of the packing line, before filling and sealing.

The erector opens the flat, folded blank into a square tube and closes the bottom, leaving the top open for filling. If done by hand, each carton requires folding and taping the bottom flaps before filling can begin; a case erector removes this step from the packing table.

On a packing line, the usual sequence is to erect the carton, fill it, close and tape the top, then label, strap, or stack the carton on a pallet.

All three machines in this category are suitable for standard cartons supplied flat, with the side seam already joined by the carton manufacturer and four bottom flaps. The erector opens the flattened tube and closes the bottom, but does not form the side seam.

The method used to close the bottom affects your packing line. A carton with a taped bottom from the AUTOBOX or AUTOBOX10 can be moved on a roller conveyor to a filling station further along the line, as the tape keeps the flaps secure during transport. A carton from the FLEX BOX has its bottom flaps only folded and held, so it is filled while standing on the machine and then sent directly to the case sealer after filling.

Automatic carton erector models: AUTOBOX and AUTOBOX10

AUTOBOX takes blanks from a sloping or horizontal worktable. Suction draws one blank at a time into the machine, which opens it, folds the bottom flaps, and applies tape to the bottom. It can process up to 16 cartons per minute, depending on carton size. It features a Siemens PLC with a touch screen and is set to the required carton size before the run. It uses BOPP or paper tape, 48 mm as standard.

AUTOBOX10 takes blanks from a magazine using suction cups. It erects 10–15 cartons per minute. The touch screen provides automatic and manual modes and stores up to 10 carton sizes. A servo sets the carton width; guides, belts, and suction cups are adjusted by hand. It tapes the bottom with 50 or 60 mm tape, with 75 mm available on request.

With AUTOBOX, flat blanks are stacked on the worktable. The sloping worktable holds around 80 double-corrugated blanks, while the horizontal version holds about 150. If thinner board is used, more blanks can be stacked.

It handles cartons 250–530 mm in length and 150–400 mm in width. Tape heads for 60 or 72 mm tape can be built to order.

AUTOBOX10 folds the front, rear, and side flaps of the bottom, then applies tape. The machine pushes the erected carton out on its belts; its manual mode operates step by step.

The carton size ranges for AUTOBOX and AUTOBOX10 overlap but are not identical. For instance, a carton narrower than 200 mm fits only the AUTOBOX, which starts at 150 mm wide. A carton shorter than 250 mm fits only the AUTOBOX10, which starts at 200 mm long.

Both AUTOBOX and AUTOBOX10 continue to run as long as there are blanks on the worktable or in the magazine. The operator is responsible for refilling blanks to keep the line moving. On AUTOBOX10, a counter can be set to stop the machine after a specified number of cartons. For example, if you need to pack a fixed batch, the machine will stop automatically when the count is reached. Pressing Clear allows the machine to continue for the next batch.

The AUTOBOX10 includes a manual debugging mode, where each press of the step button advances one stage of the cycle: taking the carton, folding the front flap, folding the rear flap, folding the side flaps, pushing the carton out, and resetting. There is also an ‘open a case’ function to erect a single carton. After changing size, this function can be used to check one carton before starting automatic operation. Ensure the corners are square, the flaps are flat, and the tape is centred.

On the AUTOBOX10, the actual width of the carton is entered for each stored carton number. When a carton number is selected, the servo adjusts to that width. The centre point for this measurement is set at the factory and does not require adjustment.

Compare case erectors by type, size, and speed

The table below compares each case erector by type, carton size range, output per minute, how blanks are fed, and how the bottom is closed. Use this to determine which machine meets your needs.

To use the comparison table, first check the carton size range for each machine to see which matches your cartons. Next, review the output per minute to ensure the machine’s speed fits your packing rate. The final two columns show how blanks are fed (by the operator, from a worktable, or from a magazine) and whether the machine tapes the bottom or leaves taping to the case sealer. The AUTOBOX and AUTOBOX10 are the models that tape the bottom.

FLEX BOX semi-automatic case erector: operator and machine

With the FLEX BOX, the operator removes a flat carton from the shelf, opens it, and folds the front and rear bottom flaps as the carton is placed on the machine. Two air cylinders then fold the left and right bottom flaps and hold the base closed while the operator fills the carton.

A push button or foot pedal activates a pusher, sending the filled carton into a case sealer, which applies tape to the top and bottom. The FLEX BOX achieves 6–7 cartons per minute with an operator working at each carton. The worktable height can be set between 700 and 800 mm.

Once the carton is positioned on the machine, it remains there for filling. The FLEX BOX acts as both the forming and filling station. After filling, the operator manually folds the top flaps.

Adjust the worktable height to suit both the case sealer and the operator. Carton length is set using the adjustment knob on the carton feeder. The product page lists our semi-automatic case sealer as the compatible machine for the FLEX BOX.

With the FLEX BOX, the carton is filled while it stands on the machine, so the output of 6–7 cartons per minute includes the time for opening, loading, filling, folding the top flaps, and pushing the carton into the sealer. This means each carton takes roughly 9 to 10 seconds from start to finish. If the items to be packed are not ready, output will decrease, as the next carton cannot be started until the previous one has left the machine.

The regulator on the air filter controls the speed of the pusher that moves the filled carton into the sealer. The pusher must move the carton firmly but smoothly, to avoid shifting the contents. Before use, ensure the FLEX BOX is level on stable ground, with castors locked and covers fitted. If the machine is not aligned with the case sealer, the pusher will send cartons in at an angle.

Carton sizes, tape widths and changing sizes

To select the correct machine, measure the smallest and largest cartons you pack, including length, width and height. Compare these with the ranges: AUTOBOX handles cartons from 250–530 mm long and 150–400 mm wide, while AUTOBOX10 covers 200–500 mm long, 200–400 mm wide and 150–350 mm high. For FLEX BOX, refer to the carton sizes listed on its product page.

For AUTOBOX10, also check two combined measurements: length plus width must not exceed 900 mm, and half the width plus the height must not exceed 550 mm. Check both for your largest carton.

Tape width is specified when ordering. AUTOBOX uses BOPP or paper parcel tape, 48 mm as standard, with 60 or 72 mm tape heads available to order. AUTOBOX10 accepts 50 or 60 mm tape, with 75 mm available on request.

Changing size on AUTOBOX10 is done by selecting the stored carton number on the touch screen. The servo sets the width, and you adjust the guides, belts and suction cups by hand. Up to 10 carton sizes can be stored. AUTOBOX is set to the required carton size before the run and can be built for other sizes if needed. Grouping orders by carton size reduces the number of adjustments. Always ensure the case sealer after the erector can handle all sizes you run.

Always compare the size ranges to the erected carton, not the flat blank. The AUTOBOX10 manual asks you to confirm the size of the carton after forming before making any adjustments.

Changing size on the AUTOBOX10 follows a set sequence: return the servo to zero, select the carton number, set the belts, adjust the magazine rails, set the carton bracket height, set the press guide plate height, adjust the forming positioning rods, set the forming bracket, adjust the suction cups, and finally set the push rod. The suction cups are set after the belts, rails, brackets and rods, as their position depends on those settings. When switching from a larger to a smaller carton, lower the suction cup holder, as the press guide may obstruct it. For a larger carton, extend the push rod without letting it touch the suction cup holder. None of the three machines automatically adjusts to each carton. If you run mixed carton sizes within the same hour, each change requires a new setup.

Choosing between semi-automatic and automatic box erectors

A semi-automatic box erector such as the FLEX BOX is suitable for lower output or frequent size changes, as the operator is involved with every carton.

An automatic box erector such as the AUTOBOX or AUTOBOX10 forms and tapes each carton in the same way, so the operator only needs to refill the blanks. These models are ideal for a steady flow of cartons. The filling step determines the pace of the line: if the box erector produces more cartons than can be filled, a queue will form. All three models can be adjusted to different carton sizes within their range.

To choose the right machine, count the number of cartons you pack during your busiest hour and the number of staff available. Compare these figures with the speeds shown in the table.

Space is also important. The AUTOBOX measures 3045 × 1855 × 1300 mm with the sloping worktable and 3045 × 2444 × 1300 mm with the horizontal one. AUTOBOX10 is 2020 × 2080 × 1396 mm. Allow space around the machine for loading blanks and for maintenance access.

Calculate the time per carton to check whether your filling and sealing steps can keep up. On the AUTOBOX10, 10–15 cartons per minute means one carton every 4 to 6 seconds. This is the rate at which open, bottom-sealed cartons will be ready for filling.

With the FLEX BOX, one person opens, fills and sends each carton into the sealer. With the AUTOBOX or AUTOBOX10, erecting is separate from filling. You need to plan who will refill the blanks and where the open cartons will be held for filling.

An automatic erector requires someone able to set it up correctly. On the AUTOBOX10, changing size follows the adjustment sequence in its manual. Cylinder and air settings should only be handled by trained staff.

Blanks, wear parts and box erector adjustments

A box erector requires flat, dry blanks. Warped or damp blanks are difficult to pick up, may open unevenly or jam in the machine. Store blanks flat, dry and off the floor. Suction cups hold the blank by vacuum. Worn or dirty cups lose grip; check them regularly on the AUTOBOX and AUTOBOX10.

On the AUTOBOX10, the belts should just touch the sides of the erected carton. If too tight, the carton will deform. If too loose, it will not be pushed out. The press plate should be set about 5 mm above the carton. Incorrect settings can cause gaps in the bottom tape or prevent the carton from leaving the machine. A blunt blade on the tape head will result in a rough cut.

The manufacturer of the AUTOBOX recommends keeping spare suction cups available.

If the main air regulator on the AUTOBOX10 cannot maintain its set pressure, the air supply is insufficient and the suction pick-up will fail. The blade and springs in the tape head are wear parts on the AUTOBOX.

On the AUTOBOX10, the magazine rails should be set to leave a gap of about 5 mm between the flat carton and the side guide plate. This allows the carton to slide easily when picked up by the suction cups. Rails set too tightly will hold the carton back in the magazine.

The AUTOBOX10 picks up the carton on its wider side, with the outer edge of each suction cup about 15–20 mm from the carton edge. Set these after adjusting the magazine rails, brackets and positioning rods, otherwise the pick-up will not work.

The forming bracket on the AUTOBOX10 must be set to match the length of the carton. If this is not done correctly, the carton may come out misshapen, diamond-shaped, damaged or become stuck in the machine. Always ensure the erected carton is square before starting a production run. The thickness of the board also influences how the carton forms. The knobs on the cylinders adjust their push and return speed, but these should only be set by trained personnel and only after the forming positions and carton sensors are correctly adjusted. The AUTOBOX is supplied with a spare blade, spare tape-head springs, screws and hand tools, so you can replace the first blade or spring without waiting for additional parts.

Factors affecting the price of a box erector

The price of a box erector is determined by whether it is semi-automatic or automatic, if it applies tape to the bottom, the type of worktable, tape heads and whether carton sizes are made to order. Ongoing costs include parcel tape, compressed air and wear parts such as suction cups, the blade and springs in the tape head, and the belt.

FLEX BOX does not use tape itself, as taping is carried out by the case sealer after filling. Each product card features a Get offer button for a quotation, for example if you require an erector together with a case sealer, and an Add to inquiry button to gather several products into one request.

For the AUTOBOX, a higher worktable or blanks fed from the left instead of the right can be made to order. If you require either option, please include this in your inquiry along with the machine.

With the FLEX BOX, a case sealer placed immediately after it is part of the set, as the bottom is only taped at that stage. For the AUTOBOX or AUTOBOX10, the top can be closed by a case sealer you already own, provided it accepts the same carton sizes. Wear parts on the AUTOBOX include more than just the suction cups and tape head: the manufacturer’s list also covers the vacuum generator, cylinders, linear bearings and valves.

Compressed air, electrical supply and safe operation of box erectors

All three box erectors require both compressed air and electrical power. FLEX BOX operates on 220 V, 50 Hz, 600 W. AUTOBOX uses 220 V single phase, 50/60 Hz, 400 W. The air unit needs regular attention: drain water from the air filter frequently. Always switch off the power and disconnect the air before carrying out any work on a box erector. Do not wear loose sleeves, ties, rings or watches near a machine with belts and moving arms.

AUTOBOX10 will only begin its automatic cycle once the servo has returned to zero and the cylinders are in their start position. FLEX BOX will shut down if the control panel is opened while running. The bottom drive chain on FLEX BOX should be lubricated weekly, and bolts and screws checked regularly.

FLEX BOX uses compressed air for the flap cylinders and the pusher, while AUTOBOX and AUTOBOX10 use it for their cylinders and the suction pick-up. Plan to have an air line available at the packing area.

The AUTOBOX10 will stop automatically when the carton counter reaches the preset number. Pressing Clear allows it to continue. Settings for the pneumatic valves are for trained staff only.

Maintenance for the AUTOBOX10 includes cleaning, lubricating moving parts, checking air pressure and inspecting suction cups and belts for wear.

On the AUTOBOX, the vacuum for the suction cups is generated by a vacuum generator powered by compressed air. If the air supply is insufficient, cartons may not be picked up, as also noted in the AUTOBOX10 manual.

The AUTOBOX has IP54 electrical protection, meaning it is safeguarded against dust and splashing water. Its noise level is up to 75 dB.

Before making any adjustments to the AUTOBOX10, switch off the power, disconnect the air and clear the area on, under and around the machine. If someone is caught by a moving part such as a belt, switch off the power first, then free the person. The FLEX BOX is plugged into a socket, not hardwired. Its power switch should be off before connecting, and the emergency stop is checked when the air is connected. The AUTOBOX10 position teaching screen is password protected. Keep the login details with the responsible person.

Checklist before purchasing a box erector

Before purchasing a box erector, confirm the carton sizes: length, width, height, smallest and largest. Know the peak number of cartons per hour, how many sizes you run and how often they change. Check the width of parcel tape you use, the compressed air and power available at the packing area, and the space for the machine.

Decide on the direction of product flow and the height of tables and roller conveyors. The case sealer following the box erector must accept the same carton sizes. A roller conveyor between the box erector, the filling station and the case sealer transports the open cartons. These points help ensure the machine fits your packing line.

Count the number of cartons you need to pack per hour at peak times. Decide whether you require an operator at the machine, as with FLEX BOX, or if you need an automatic erector such as AUTOBOX or AUTOBOX10.

Pay attention to the direction of flow. AUTOBOX takes blanks in on the right and sends cartons out on the left as standard. The opposite direction can be made to order.

Match the heights of your equipment: FLEX BOX worktable is adjustable from 700 to 800 mm, AUTOBOX is 650 mm as standard and up to 1000 mm made to order, AUTOBOX10 is 650 mm. Choose the parcel tape width when ordering. The AUTOBOX is specified for -10 to 40 °C and humidity up to 98 percent, so check if your dispatch area remains within these limits.

If your new machine will be used with a case sealer you already own, include that sealer’s model and working height in your inquiry. This allows carton sizes and heights to be checked for compatibility with both machines.

Frequently asked questions about box erectors

Which box erectors apply tape to the bottom of the carton?

Both AUTOBOX and AUTOBOX10 tape the bottom of the carton after folding the flaps. FLEX BOX does not tape the bottom; it only folds and holds the flaps.

Do these box erectors require compressed air?

All three box erectors in this category need compressed air to function. This is required for operations such as suction, folding flaps or driving the pusher.

How many cartons per minute can each box erector produce?

FLEX BOX produces 6–7 cartons per minute with an operator. AUTOBOX10 produces 10–15 cartons per minute. AUTOBOX can produce up to 16 cases per minute, depending on carton size.

Can a single box erector handle different carton sizes?

Yes, each box erector can be adjusted for different carton sizes within its range. AUTOBOX10 stores up to 10 carton sizes and uses a servo to set the width. AUTOBOX is set to the carton size before the run. FLEX BOX is adjustable to the carton size.