The Cartoner has been a major machine deciding the production capacity of a packaging line.
The cartoner may have the basic types classified as follows: (1) semi-automatic cartoner and fully automatic cartoner in aspect of operation means; (2) vertical cartoner and horizontal cartoner in aspect of cartoning direction; (3) Continuous cartoner and intermittent cartoner in aspect of movement.
According to the definition, it can be known that the semi-automatic cartoner requires the operator to fill products into cartons; this machine takes cartons from the carton-storing device, and seals the bottoms after the cartons take form and are filled with products. With regard to fully automatic cartoner, products are automatically filled into the cartons.
On the vertical cartoner, the open cartons go vertical through the machine, and products are passed or automatically filled into the cartons from top of the cartons. On the horizontal cartoner, the cartons are laid horizontal to go through the machine, and products are filled into the cartons from the side. Figure 1 shows the conveying means of packaged biscuit and standard bottles. By comparison, it can be known that conveying means to be used by cartoners may vary greatly.
Carton pattern
Standard carton patterns: Tuck-in closure with airplane flaps; Tuck-in closure with reversed flaps; Combination tuck-in and hot-melt closure; Double-sided hot-melt closure; Hot-melt closure with fourth flap-reclosable .
Semi-automatic Cartoner
The semi-automatic cartoner applies to a packaging line with frequent change of carton sizes, as it features a wide range of optional sizes and short time of replacement. For the semi-automatic cartoner, the cartoning speed is commonly 30-150 cartons/minute. As products are filled into the cartons manually, much cost is saved. The semi-automatic cartoner may complete all other specified actions when the operator moves.
Most semi-automatic cartoners have U-shaped carton conveying belts for the operator to carry out manual feeding on either side of the conveying belt.
The standard vertical cartoner has various auxiliary devices, in which the digital printer and printing mechanism are the most common.
Some semi-automatic vertical cartoners have pre-folded lining paper feeding mechanisms. Most of such mechanisms take folded lining paper out from the paper-storing device and make it U-shaped and partially inserted into the moving cartons. When products are manually filled, the lining paper is pressed to bottom of the cartons. On the vertical cartoner, the cartons are sometimes placed upside down; cartoning in such a way makes the lining paper on top of the cartons, providing convenience for use.
Some vertical cartoners are installed with a special mechanism, which allows products to be filled from upside of cartons. Generally, machines with such mechanism are specially designed for individual and particular needs.
Figure 1 A – Conveying means of packaged biscuits B-Conveying means of standard bottles Mobility is a major advantage of the vertical semi-automatic cartoner. Most of such machines are installed with casters, providing convenience for moving the machine from one production line to another.
Fully automatic Cartoner
Generally speaking, the modern fully automatic cartoner features higher production speed and smaller applicable size range than semi-automatic cartoners.
The horizontal cartoner may directly be used with the tubular filling machine, or with the automatic product feeding device at the preceding procedure of the production line. The fully automatic horizontal cartoner has the production speed ranging from 50-600 cartons/minutes, or some even exceeding 600 cartons/minutes.
Similar to the semi-automatic machines, these machines are also equipped with various auxiliary devices. The product description, set price, quantity and other data can be printed or printed on the cartons; some can be printed on the end face of the cartons. The horizontal cartoner can also print or press required marks in front or on side of the cartons after taking the cartons from the box-storing device and before opening it.
Many fully automatic cartoners are installed with lining paper treating mechanism, which is applied to pre-folded lining paper, die-cut paper sheets or lining paper roll. The lining paper roll has many prominent advantages than the die-cut paper sheets. Due to consecutive movement of the lining paper roll, it has higher speed; as the lining paper is wound on the roll, possible deviation during operation is eliminated.
Fully automatic exterior packaging machine
Currently, multi-piece cartoning becomes a trend of packaging, and hence the exterior packaging machine is generated. The multi-piece exterior packaging machine is designed to pack a certain quantity of the same products in a single box. Featuring intermittent movement and periodical operation, this kind of machine is applicable to filling flat disc boxes, cartons, cylindrical boxes or various types of exhibit boxes.
As the machine requires a certain quantity of products to be gathered before packing, the packing speed is commonly slow (5-50 cartons /minutes). However, the machine has rather high speed for transmitting products, and thus it is critical for highly efficient production.
Product conveying system
The fully automatic packaging machine can be equipped with various automatic conveying mechanisms. For example, when bottles or cans are transmitted, bottles and cans are generally transmitted vertical on the platform conveyor chain into the packaging machine, and the product transmitting mechanism applies the consecutively running delivery wheel to regularly convey the bottles to the chute on the conveying belt of the packaging machine.
Both metallic and plastic tubes can be directly and automatically conveyed to the chute of the packaging machine via a tubular filling machine. To obtain a high speed, multiple tubular filling machines can be set along the product conveying line. The cartoner may also work simultaneously with the wrapping to convey one or more bags to the conveying belt with a chute.
The conveying devices for several other special products (such as packed biscuits, chalks, pencils, developing paper and films etc.) can mostly apply to the cartoner with a conveyor.
For products that may flow freely, on the fully automatic vertical cartoner, a measuring cup can be used to measure the volume. The measuring cup is simultaneous with the boxes, and when the box is below the filling mouth, measurement of the volume is taken. Products such as rice, candies, cleaning powder and the like generally adopt such method for packaging. The machine can also be equipped with a net weight scale simultaneous with the moving cartons.
In other cases, the products to be filled must be counted, such as nuts, screws and other small hardware products.
Filling and opening of cartons
The mechanism for feeding and opening of cartons is the most critical for cartoners. Though there are many types of feeding mechanisms on the market, most are for vacuum feeding. As required for higher speed, most repetition is substituted by rotation. Today, the manufacturing technology of cartons makes it possible for the packaging industry to adopt simpler mechanisms. Under the premise of no cost increase, the industry is exploring even simpler methods.
Filling
The filling system of most consecutively running horizontal packaging machines comprises a pair of parallel chains with support of a feeding slide bar. The feed conveying chain, product conveying belt and carton conveying belt are simultaneous. The feed slide bar is controlled via a cam, so that products are filled into cartons one by one in several mechanical circulations.
Carton sealing
Another key mechanism of the horizontal packaging machine is the carton sealing mechanism. When folded cartons are conveyed, the mechanical folding device or adhesive tape cap sealer is used. Cold glue (dextrin or resin) or hot-melt adhesive is used. A spray gun or gear is used for gluing. When single-layer adhesive is applied, only the exterior bottom cover is bound. When double-layer adhesive is applied, the interior bottom cover shall be hound to the side covers first, and then the exterior bottom cover bound to the interior bottom cover.
Figure 3
The semi-automatic vertical cartoner typically adopts U-shaped carton conveying belt, so that the operator may fill products on the open cartons on either side of the U-shaped belt. In addition, various accessories can be selected as required.
Recent development trend of cartoning equipment
Today, the cartoning equipment industry develops with significant and notable trends. (1) the machines become easier to be cleaned with gradually promoted efficiency; (2) the machines have greater storing capacity; (3) the machines realize sealing of the side clearances on the production line. Therefore, there are fewer requirements for the operators in aspect of equipment maintenance.
Less maintenance of the machines still contributes to (1) no regular lubrication required in most cases; (2) high-speed integrated driving system; (3) transmission gear socked in oil and design of a firm base.
The equipment design becomes more compliant with the sanitary requirements in the following aspects. (1) Bosses or grooves that may catch surplus products and dust are reduced; (2) relatively cleaner area shall be at the lower part of the machine for convenient cleaning.
Realization of higher speed is attributable to installation of multiple cartoning systems on the same site to provide more products. Less effort is required for each packing procedure. The machine becomes more flexible, as many parts are adjustable.
Jornen Machinery
31/7/2013