Is It Worth Investing in a Case Packer Machine?
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Handling tertiary packaging like case packing is by no means an easy task.
Corrugated shipping cases are large and require heavy lifting. The fact that shipping case packaging is of large volume and packed largely results in the tasks of assembling the case, placing the products, sealing, and labelling also being physically and mentally demanding.
To solve your doubts and to provide insights for those who are looking to automate their tertiary packaging, we discuss in this session the essentialness of case packing, then reach to the topics about selecting case packers and how to find the right manufacturer for such packaging machines.
What is Case Packing as a Tertiary Packaging?
Moving commodity from one location to another in large quantity is the nature of distribution and an essential part of supply chain. Serving here as the medium for bulk handling, providing protection during transportation and facilitating logistics is the tertiary packaging that involves the use of corrugated carton boxes or sometimes cartons of combined materials such as recycled paperboard covered with kraftpaper – providing similar strengthness to corrugate cardboard.
Case Packing Samples
Credit: ELITER Packaging Machinery
The case packing can refer to a larger packaging that keeps in multiple arrangment within the packaging products either in secondary packaging (basically smaller cartons) or directly in primary packaging (cans, bottles, pouches, etc.), and the size of the “case” may range rougly from 200*200*150 to 450*450*300 mm.
What are the Typical Options of Case Packers on the Market?
While with a quick search on Google or Youtube you may find an abundant array of case packing machines and manufactures or distributors who are showcasing their equipment, deciding on what kind of machine to invest is not supposed to be made out of a sudden whim. Just like all the other packaging equiment, case packing machine has its own variety in accordance to its operation pattern and sequence.
- Horizontal End-Load/Side-Load Case Packers: Side load case packers are similar to a cartoner in terms of the operational sequence, but varies in the sizes of the final packaging and what are to be loaded.
- Top Load Case Packers: Products are loaded into the case from above. These are ideal for products that are best suited to being stacked or that need careful placement within the case.
- Wrap-Around Case Packers: A wrap-around case packer applies flat unglue corrugated blank and follows a wrap-around packaging process to form the packaging, usually with adhesive used. It resembles the side-load case packing process but varies in the blank used.
Why Should You Not Consider the Low-End Combined Case Packing System?
We are referring to a low-end case packaging system that is dumb in approach that is actually composed of three kinds of packaging equipment that is connected to automate the process of erecting the corrugated box, loading the products and completing the tape-sealing which is supposed to be handled in a single set of machine if done with state-of-art mindset of engineering.
Such kind of low-end machines, consisting usually of a carton erector, top loading machine, and a carton sealer, are typically found on the market especially with a random search on platforms like Alibaba or Made-in-China where they are peddled by some random resellers and trading companies, or sometimes a low-end equipment manufacturer.
Automating a packaging process with 3 machines is not an ideal approach of packaging automation engineering. Such kind of case packing systems are admittedly affordable, however, the fact that they are combined in nature of 3 machines brings a range of disadvantages and potential issues for the machine’s reliability during the long run, as well as the complicated maintenance works.
Such a Case Packing System Takes more Space
Such a system takes more space compared with a genuinely developed and designed case packer now that 3 machines should be solidly connected to each other to automate the process. In most of the cases, it will take a space of some 6500*3000 mm, which is some 19.5 square meter and then 2 meters in height. Equipment is such a dimension and size can be a problem especially for SMEs who are renting for production facility or whose facility is of limited space availability.
Combined Case Packing System is more Vulnerable to Downtime
Potential downtime can be timed for reason of 3 machine being combined. The chance that an integrated packaging system suffers from downtime is not an addition but a multiplication.
In probability theory, when you want to find the likelihood of multiple independent events all happening, you multiply their probabilities. For example, if Machine A has a 90% uptime and Machine B also has a 90% uptime, the probability that both will work at the same time is 0.9 x 0.9 = 0.81 or 81%.
What are the Issues with Manual Case Packing?
Packing manually the shipping case or corrugated carton will bring potential drawbacks to either the employer or the employee.
For employees, the fatigue and physical strains led by moving such giant articles and units of packaging, assembling, tipping, and tapping can cause occupational diseases including wrist and hand strenuousness in the long run.
For employers, the manual packaging process of shipping cases and corrugated boxes leaves potential labour risks and hazards like accidents of crushing injury against the staked heavy cases. A hazardous workplace has immense and unpredictable risks, either in terms of labour safety or legal issues. Manual packing can also take up more space, as people need room to move around, and the cases may need to be stored differently – which reflects an increased operational cost.
A Client’s Facility that Relies on Manual Case Packing
Credit； ELITER Packaging Machinery
Is it Worth Investing in an Automatic Case Packer Machine?
We will not be talking merely about the benefits of automated case packing to convince people to purchase a case packer unscrupulously without study into their own situations and considerations in advance, now that the case of each company may vary and it should be based on their own analysis on their operation cost to decide whether to keep with manual process or opt for an automated case packer.
The short answer is that, as long as you sees the potential of constant growth in the future, investing in a case packing machine will save a lot of cost for your business. However, to focus on the short run, factors should be taken into consideration to hammer out a decision whether it is worth purchasing such a deluxe equipment, they may include but are not limited to the following concerns:
Analyse Your Current Packing Process:
- Evaluate the efficiency, throughput, and cost of your current packing process.
- Identify bottlenecks, labor costs, and the potential for human error.
- Determine the volume of your operations and whether it is expected to increase in the future.
Calculate the Potential Return on Investment (ROI):
- Estimate the savings on labor and material costs after shifting to automation.
- Factor in the increased productivity and capacity for greater throughput.
- Consider indirect savings from reduced workplace injuries, improved product protection, and less material waste.
Look at Future Growth:
- If your business is expanding or plans to introduce new product lines, an automatic case packer could offer the scalability you need.
- Assess whether the machine can adapt to various sizes and specifications of packaging without incurring significant modification costs.
Assess the Space Available:
- Automatic case packers require a certain amount of space. Ensure your facility can accommodate the new equipment without disrupting current operations.
Consider the Skill Level of Your Workforce:
- Will you need to train employees to operate the new machinery?
- Weigh the costs of training against the long-term gains in productivity and efficiency.
