Cardboard packaging: steps and machines

Packing into cartons with cardboard packaging starts with a case erector. The case erector forms a carton from a flat blank and closes the bottom. The carton is then filled by hand or machine. A carton sealer closes and tapes the top of the carton.

You can choose semi-automatic machines, where the operator works with the machine, or automatic machines, which run by themselves once set. FLEX BOX and FLEX TAPE are semi-automatic. AUTOBOX10, AUTOBOX, TOP TAPE, AUTO-TAPE and AUTO&FOLD-5050 are automatic.

The carton sealer is responsible for closing and taping the top of each carton. Conveyors connect the machines and move cartons between stations, reducing manual handling. For example, after a case erector forms and seals the bottom, the carton travels by conveyor to the filling area, then to the carton sealer, and finally to the palletizing area. Each machine is set up for its specific task, so the process moves smoothly from one step to the next.

Semi-automatic machines like FLEX BOX and FLEX TAPE need an operator at every carton, which means someone is always present to load, hold or guide the carton through the machine. Automatic machines such as AUTOBOX10, AUTOBOX, TOP TAPE, AUTO-TAPE and AUTO&FOLD-5050 run by themselves once set. The speed of the line depends on the slowest step, often the filling. If the filling is done by hand, the output will match the pace of the operators. If it is automated, the machines can run at their rated speeds.

Case erector models for cardboard packaging

AUTOBOX10 is an automatic case erector for 10–15 boxes a minute, up to 720 an hour. It handles cartons 200–500 mm long, 200–400 mm wide and 150–350 mm high. It draws a flat blank from its magazine, opens it, folds the bottom flaps and tapes the bottom. It is pneumatic and stores up to 10 carton sizes.

AUTOBOX is an automatic case erector for 16 boxes a minute with Siemens PLC control. FLEX BOX is a semi-automatic case erector where the operator works with the machine.

Because the AUTOBOX10 is pneumatic, it needs a supply of compressed air to work. It can store up to 10 carton sizes, so if you switch between standard sizes, you can recall a stored setting instead of adjusting from scratch. This saves time during changeovers and reduces the chance of setting errors.

With any erector, the blanks must be dry and flat. A damp or bent blank may not open properly, which can stop the line or cause a jam. Blanks stored in a humid area can warp, and the erector may then fail to pick or open them.

Case packing machine comparison table

The table below lists the main figures and settings for each cardboard packaging machine. Compare output, carton sizes, tape widths and features.

To read the comparison table, start with the type of machine: case erector or carton sealer, and whether it is semi-automatic or automatic. Next, look at the figures for output per minute and the carton size range. Then check the tape width each machine uses. For example, if you need to seal cartons with tape 48 mm wide, confirm that the machine accepts this width. If a model name does not give a figure, such as the exact output or size range, you can find these details on the product page. This helps you match the machine to your cartons and output needs.

Carton sealer and box taping machine options

FLEX TAPE is a semi-automatic carton sealer for tape 48–72 mm, Kraft or BOPP. TOP TAPE and AUTO-TAPE are automatic carton sealers for tape 48–72 mm, Kraft or BOPP. AUTO&FOLD-5050 is an automatic box taping machine that folds the top flaps and adjusts to the carton width and height by itself.

FLEX TAPE is a semi-automatic carton sealer, so an operator is present to guide each carton through the taping process. TOP TAPE and AUTO-TAPE are automatic carton sealers, which means that once the cartons are placed on the infeed, the machines close and tape the tops without further handling. All three models take tape 48–72 mm wide, and you can use either Kraft (paper) or BOPP (plastic) tape, depending on your preference or the requirements of your shipping process.

The AUTO&FOLD-5050 is an automatic box taping machine that closes the top flaps itself in a set order: first the front, then the rear, then the sides. It adjusts to the carton width and height using air cylinders, so it can handle mixed carton sizes without manual adjustment. The carton length is set with a micro switch. This setup is practical on a line where carton sizes change often, as the machine adapts automatically and reduces the risk of taping errors or jams caused by incorrect settings.

The AUTO&FOLD-5050 handles cartons 200–600 mm long, 150–500 mm wide and 150–500 mm high. It uses tape 48–60 mm wide, Kraft or BOPP, and the belt speed is 16 m/min. The table height can be set from 600 to 850 mm to fit your line. It runs on 220 V and needs compressed air. In practice, keeping spare tape rolls at the sealer ensures that roll changes are quick, usually taking only a minute. If tape runs out and no spare is at hand, the line can stop while an operator searches for a new roll.

Roller conveyor choices for cardboard packaging

The Extend stainless-steel roller conveyor is 550 mm wide and can be extended from 1200 to 5000 mm. This allows you to set the conveyor length to fit the distance between machines or workstations. For example, if your packing area is rearranged, you can adjust the conveyor to match the new layout. The stainless-steel construction is suited to warehouse and production environments where durability and easy cleaning are important.

The flexible conveyor is 460 mm wide, 1200–4800 mm long and 600–1000 mm high. You can extend, shorten or bend it around corners to fit your space. This is useful if your packing line changes direction or if you need to move cartons around obstacles. For example, on a busy production floor, you might bend the conveyor to feed cartons from the sealer to the palletizing area, saving space and reducing manual handling.

The powered flex conveyor comes in 4 m or 6 m lengths and moves cartons at 15 m/min. Unlike a gravity or push roller conveyor, it moves the cartons itself, so you do not need to tilt the line or push the cartons by hand. The LOADER UL1790 is designed for truck loading and unloading, with a belt conveyor 790 cm long and a roller conveyor 1000 cm long, both 80 cm wide. This setup reaches into the truck so cartons can be loaded or unloaded directly, reducing manual lifting and speeding up the process.

Packing tape for carton sealers

BOPP packing tape is 48 mm wide and 66 m a roll, in brown or transparent. It is supplied by the box with 72 rolls or by the pallet with 3024 rolls. FLEX TAPE, TOP TAPE and AUTO-TAPE take tape 48–72 mm, Kraft or BOPP. AUTO&FOLD-5050 takes tape 48–60 mm, Kraft or BOPP.

BOPP tape is made of plastic, while Kraft tape is made of paper. FLEX TAPE, TOP TAPE and AUTO-TAPE accept tape widths from 48 to 72 mm, and the AUTO&FOLD-5050 uses tape 48–60 mm. The 48 mm BOPP tape fits all four models, so you can standardize on one tape size if you use several machines. Having the correct tape width for your sealer prevents jams and poor seals, which can cause cartons to open during handling.

Semi-automatic or automatic cardboard packaging

A semi-automatic machine like FLEX BOX or FLEX TAPE works with the operator at each carton. This setup suits lower output and frequent changes in carton size. For example, FLEX BOX is a semi-automatic case erector, and FLEX TAPE is a semi-automatic carton sealer for tape 48–72 mm, Kraft or BOPP.

Automatic machines such as AUTOBOX10, AUTOBOX, TOP TAPE, AUTO-TAPE and AUTO&FOLD-5050 run by themselves once set. If your cardboard packaging line needs a steady flow of cartons, an automatic model can form or seal each carton the same way without an operator at every step. AUTOBOX10 can process 10–15 boxes a minute.

To choose between the two, count how many cartons you pack per hour now and plan for your busiest periods. Compare this number with the output figures in the comparison table. For example, if your peak is 600 cartons an hour, a machine rated for 10–15 boxes a minute can match the pace. If your output is much lower, a semi-automatic model may be enough, especially if you switch carton sizes several times a day.

Mistakes can happen if the machine output does not match the pace of the rest of the line. If an automatic sealer is set too fast for the filling step, cartons may pile up and cause jams. If a semi-automatic machine is too slow, you may see a backlog at the packing station. Matching the machine to your actual and peak output helps keep the line running smoothly and avoids these problems.

Packing one carton size or mixed sizes

If you pack one carton size in long runs, a machine set to that size works through the whole run without a changeover, so the time for setting the size is spent once.

When you pack mixed carton sizes, a machine that adjusts itself is more practical. The AUTO&FOLD-5050 adjusts the width and height automatically with air cylinders and sets the carton length with a micro switch. The AUTOBOX10 stores up to 10 carton sizes, so a size you use again is recalled instead of set from the start.

To reduce the number of changeovers, group your orders by carton size where possible. For example, if you have orders for products that fit the same carton, run them together before switching to a different size. This way, the machine stays on one setting longer, and you spend less time adjusting. Each changeover is a chance for mistakes, such as setting the wrong size, which can cause jams or poor sealing.

What affects the price of case packing machines

The price depends on whether the machine is semi-automatic or automatic, the output per minute, automatic size adjustment and if the machine folds the flaps. Tape is the main running cost. The price for each model is shown on its product card.

Tape is bought by the box or by the pallet, depending on your usage. Where a machine needs compressed air, the cost of running the compressor is part of the ongoing expense. The product cards have a Get offer button for a quote, such as for a sealer with a stock of tape, and an Add to inquiry button that lets you collect several products into one request. This helps you compare options and plan your purchase.

What to check before ordering cardboard packaging

Before ordering cardboard packaging equipment, check your carton sizes, the number of cartons an hour, and if you pack one size or many. The tape type matters: FLEX TAPE, TOP TAPE and AUTO-TAPE use tape 48–72 mm, Kraft or BOPP, while AUTO&FOLD-5050 uses tape 48–60 mm, Kraft or BOPP.

Before ordering, list the carton sizes you pack and how many of each you use in a day. Check these against the carton ranges in the comparison table to make sure your sizes fit the machines. For example, if your largest carton is 500 × 400 × 350 mm, confirm that it is within the range for the case erector and sealer you plan to use. This avoids buying a machine that cannot handle your main carton.

Check that you have compressed air on site if you plan to use a machine that needs it, such as AUTOBOX10 or AUTO&FOLD-5050. Measure the space available for conveyors and plan the flow of cartons from filling to stacking on the pallet. For example, if your packing area is narrow, a flexible conveyor can be bent to fit the space and connect the machines without blocking walkways.

After the cartons are stacked on a pallet, plan how to secure them for transport. A pallet wrapping machine or hand film is often used to hold the load together. This step is important to prevent cartons from shifting or falling during shipping. Planning the full process from carton forming to pallet wrapping helps avoid delays and keeps goods safe in transit.

Questions about cardboard packaging

Should I choose a semi-automatic or automatic cardboard packaging machine?

Semi-automatic machines like FLEX BOX and FLEX TAPE work with the operator. Automatic machines such as AUTOBOX10, AUTOBOX, TOP TAPE, AUTO-TAPE and AUTO&FOLD-5050 run by themselves once set.

Which tape can I use with the carton sealers?

FLEX TAPE, TOP TAPE and AUTO-TAPE take tape 48–72 mm, Kraft or BOPP. AUTO&FOLD-5050 takes tape 48–60 mm, Kraft or BOPP.

Can the machines handle mixed carton sizes?

AUTOBOX10 stores up to 10 carton sizes. AUTO&FOLD-5050 adjusts width and height automatically by air cylinders and sets carton length with a micro switch.

Which machines need compressed air?

The AUTOBOX10 and the AUTO&FOLD-5050 need compressed air. For the other machines, the supply is given on their product pages.