Mechanical Design and Engineering of 5 Mechanisms Typically Present on Case Packers
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Integrated to your packaging end-of-line at the very end of the processes are usually heavier packaging equipment like palletizers, pick-and-place robots and case packers which move items of large size and handle them “big and bold”.
As one of the most common categories of tertiary packaging equipment, case packers are recognized as the essential automation option for complete packaging line solutions. Case packers bring considerable savings to labour work, especially given the reasons that corrugated boxes are not easy to be moved manually. As an experienced manufacturer of secondary and tertiary packaging machines, we would like to share with you in this article those typical mechanisms used for the engineering and design of case packers.
This is more like an advanced article that requires some minimum knowledge around mechanical engineering so that you can get full understanding of the content. Should you have any doubt about the content, you are free to contact us by sending an email to info@eliter-packaging.com.
The Operation Principle of Case Packers
A case packer is seldomly used as a standalone machine, rather, most frequently, to be lined up with a secondary packaging machine to receive packages from upstream and to pack them in a grouped manner in corrugated cardboard cartons. The operational sequence or operation principle of case packers include a series of functions that follow one after another to automate the process of case packing for grouped secondary packages into corrugated cartons. Regardless of the types of case packers, most of them follow the below operation principle as their sequence of functions:
Product Infeed
- Sorting and Orientation: Products are first fed into the case packer system, often via conveyor belts. Depending on the type of product and the required packing orientation, products may need to be sorted, aligned, or oriented using various mechanisms such as rotary feeders or linear guides.
- Collation: Products are grouped according to the desired pack arrangement. This could involve arranging products in single or multiple layers, and in specific patterns to optimize space and ensure stability within the case.
Case Erecting
Case packers start by pulling a flat cardboard blank from a magazine. The blank is then precisely folded into a box shape. This is typically done using mechanical arms, vacuum assist, or pneumatic systems, which ensure the box is open and ready to be filled.
Product Loading
Once the case is ready, the grouped products are moved into the case. This can be done through different methods:
- Side Loading: Products are pushed horizontally into the case, useful for delicate items.
- Pick-and-Place: Robotic arms with suction or gripper tools place products into cases, ideal for irregularly shaped or fragile items.
Case Sealing
After the products are loaded, the case is sealed, typically using adhesive tape or glue. Some machines also apply strapping or wrapping to reinforce the cases, especially for heavy or bulk items.
5 Typical Mechanisms Integrated to Case Packers
Grashov Linkage
Grashof’s criterion determines the types of motion possible for four-bar linkages, which are common in many mechanical systems used in industrial applications, including packaging machinery.
In the context of case packers, Grashof linkages could be used to control the movement of parts of the machine that need to open, close, lift, or rotate — for example, to grasp products, move them into boxes, or close the boxes after packing. The use of grashov linkages can provide smooth and controlled motions that are essential for efficient and reliable packaging operations.
From Design of Machinery – Sixth Edition
Credit: Mc.Graw Hill Education
Slider-Crank Mechanisms
Slider-crank mechanisms are commonly used in case packers and various other types of packaging machinery. The slider-crank is a basic mechanical configuration that converts rotary motion into linear motion or vice versa, making it highly effective for repetitive tasks such as pushing and pulling, which are prevalent in packaging operations.
In many case packing systems, the slider-crank mechanism is used to drive pushers that move products into the packaging boxes. The rotary motion of the motor is converted into the linear motion needed to slide products smoothly into place.
Eccentric Rotary Feeding System
An Eccentric Rotary Feeding System is a specialized mechanical system used in various industrial applications, particularly in packaging and assembly processes. The core component of this system is a disk or wheel that is mounted off-center (eccentrically) relative to its rotation axis. As the disk rotates, the eccentric mounting causes the disk to wobble or oscillate in addition to its rotation.
Gran Sonata Balcony Cartoner is Designed with Eccentric Rotary Feeder
Credit: ELITER Packaging Machinery
A typical example of such mechanism on case packers is the rotary feeder that picks blanks from the magazine and erects them into side load cases with horizontal open ends. You can find more information about rotary feeder by checking one of our past blogs.
Belt Drive & Chain Drive
Belt drives and chain drives are integral components in case packers, each serving specific roles in the operation of these machines. They are typically used for transmitting power and for moving products and packaging materials through different stages of the packing process. Understanding the roles and advantages of each can provide insight into their application in case packers.
- Belt Drives might be used for driving conveyor belts that transport lightweight products or packaging materials smoothly and quietly across the packing facility.
- Chain Drives could be implemented in parts of the machine that require robust power transmission for heavy or bulk packing operations, or where precise movements are critical, such as in the precise positioning of boxes for filling and sealing.
Belt drive is a common option for building the discharge belt mechanism for case packer where folded corrugated cases are carried forward meanwhile being sealed with tape or adhesive.
Linear Guides
Linear guides are crucial components in many types of machinery, including case packers, where precision, efficiency, and smooth operation are paramount. On case packers, linear guides can be found in multiple components of the machinery:
- Loading Mechanisms: Guides are used where boxes or products must be precisely loaded into the packaging system.
- Sorting and Collating: They assist in the precise alignment and movement of products into the correct orientation before packing.
