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Case-packing gets a makeover

A high-speed case packing system cuts labor costs, frees up some folder/gluers, and increases productivity for a maker of custom corrugated containers.

MAGAZINE FEED. Photo above shows knocked-down corrugated cases stacked in a magazine feed on the left and product infeed on the
MAGAZINE FEED. Photo above shows knocked-down corrugated cases stacked in a magazine feed on the left and product infeed on the

“We’re experts in manufacturing custom corrugated containers,” says Krist Leland, director of manufacturing for Alliance Packaging. “But we weren’t experts at erecting the corrugated cases into which our knocked-down corrugated containers are inserted.”

So when the Renton, WA-based firm installed a new production line on which to make its custom corrugated containers, Leland began researching high-speed machines to replace two semi-automatic case erectors that couldn’t keep up with the new production line’s speeds. His research led to the installation of an automatic case erector/loader/sealer from Massman Automation Designs (www.massmanllc.com). The Model WACP-YE serves a manufacturing line that is used almost exclusively for one customer, explains Leland. The line produces seven different sizes of glued, full-overlap custom corrugated containers that are automatically inserted 25 at a time into corrugated cases.

A much better way

Prior to installing the Massman system, an employee stacked corrugated cases into the old case erector by hand. The machine then popped the cases open. Next, the employee manually inserted a bundle of 25 custom corrugated containers into the case. The case erector sealed the ends of the case before discharging it.

Now, the bundles of custom corrugated containers are conveyed to the Massman system, which automatically compresses them and inserts them into corrugated cases that are also automatically erected by the Massman. This eliminates the need for a worker to manually shove the bundles into the cases.

“We ran a five-person crew, and now we run a four-person crew,” says Leland. “The new machine eliminated one person per shift, and we run four shifts on that particular machine per week. From a labor standpoint, the Massman saves us about $46,000 a shift per year.”

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