Case Packers: 3 Types & 6 Considerations

Case packing involves the careful arrangement and packing of goods into cases or boxes for palletizing and shipment. Today, we still see manual case packing but a considerable amount of plants are investing in automated case packers. In some scenarios, the product dictates the type of case packer. But most often, customers have a wide range of systems to choose from while considering speed, packaging requirements, floor space, etc. While there are many types of case packer and new technologies introduced each year, in this blog post we’ll focus on the 3 most common types, and outline 6 key considerations when buying a new case packer.

3 Main Types of Case Packers:

1. Top Load Case Packers typically pack product through the top of an RSC, wraparound, or harness style case. With speeds up to 20 cases per minute, top load case packers are mostly used for bottles, pouches, and various boxed products. Depending on the application, case packers can accommodate both robotic and non-robotic pick-and-place systems. Bottom load packers are recommended for the larger products such as outdoor grills. They are used when the primary product needs to be handled carefully, as the case is pushed over the product.

2. Side Load Case Packers typically collate product and then move the grouped product horizontally into an open case, which sits on its side. With speeds up to 25 cases per minute, side load case packers are often used for rigid products, like cartons or carton bundles that can be easily stacked and pushed. Models are available with pre-stacking case conveyors, tape and glue closing, user-friendly HMI operator interface and small overall footprints

3. Wrap-Around Case Packers form cases around products, placing product from the side or top of the wraparound blank. Providing a snug fit around the product, wraparound cases typically use less corrugate and the corrugate itself takes up less space with transit/storage as it lays flat . In addition, case blank magazine capacity is maximized with a wraparound case packer holding twice as much blanks compared to RSC case packer. Producing up to 25 cases per minute, wraparound case packers are designed to run various products and its universal automatic product collating system can accept a wide range of carton sizes and pack patterns.

6 Considerations for Choosing a Case Packer:

• 1. Product Type: Each case packer suits a particular type of product. Top Load Case Packers are perfect fragile products or packages containing liquids like glass bottles, canned goods, and spray bottles. Side Load Case Packers are preferred with items that don’t need to stand upright,  or uniform stacks of cartons that are easy to aggregate and push from the side. Wrap Around Case Packers are used for larger products that are already wrapped or bundled, such as cases of bottled water or home care products.

• 2. Case Type: While the product can certainly dictate the case packer, the type of case is equally important as it pertains to maintaining the integrity of the product, stacking strength, and retail display attributes. The most common case types are 1. top load RSC (regular slotted container); 2. side load RSC or end load RSC and 3. Wraparound. In some retail stores, top load cases are preferred, as customers may buy several bottles, for example wine or liquor. Other times, when bottle or product protection is not as important, a wraparound case will suffice and take up less space in the magazine and storing flat corrugate.

• 3. Line Speed: Speed can’t be ignored as you need to align your case packing with upstream filling and production. While it’s important to match your production speeds, if you want a faster machine for future proofing, typically it will be more expensive. If your speeds are 20 cases or less per minute, a robotic case packer, side load, or bottom load case packer will typically be sufficient. For speeds over 20 cases per minute, drop packers or intermittent motion wraparound systems typically handle these speeds well.

• 4. Machine Load: When choosing a case packer, it’s a good idea to make sure the system can handle the weight load of the product in conjunction with the production demand. One effective way to determine this is by observing it in action with a similar application. Factors such as the weight of the product, actual production rates, and operational hours per week should be carefully considered.

• 5. Floor Space: The allocation of floor space is critical for any operation. The footprint of a case packer varies from type to type, including guarding if robots will be utilized. Intermittent machines tend to take up less space than continuous motion options. Robots tend make systems wider, and depending on speeds, multiple robots will need to used. Balancing functionality with space requirements ensures that line production flows smoothly and the case packer works well within the overall layout.

• 6. Changeover and Flexibility: When considering a case packer, prioritize its ability to facilitate smooth changeovers and adapt to diverse packaging needs. Overall, robotic packers are the most flexible in automation and changeover requirements. Drop packers offer more simple changeovers while wraparound is usually the least flexible when adding new packages retroactively. In addition to changeover, it’s important to investigate the compatibility with existing machinery and how user-friendly operating the machine is for your staff.