Box erectors for forming and closing cartons

Box erectors on this page form a carton from a flat blank and close its bottom, so it is ready to fill. On all three, the bottom is closed in the same order: the front and rear flaps first, then the two side flaps. On the FLEX BOX the operator closes the front and rear flaps by hand.

There are three box erectors in this category: the semi-automatic FLEX BOX and the automatic AUTOBOX and AUTOBOX10. AUTOBOX and AUTOBOX10 both tape the bottom of the carton, while FLEX BOX only folds and holds the bottom flaps for filling.

Choose your box erector by carton size, cartons a minute, operator or automatic operation, tape width and compressed air. The top of the carton is closed afterwards by one of our carton sealers. A table below the products compares the machines.

How a carton erector works in the packing line

A carton erector takes a flat blank and forms it into an open carton with a closed bottom. The front and rear bottom flaps are closed first, then the two side flaps. This prepares the carton for filling.

AUTOBOX and AUTOBOX10 tape the bottom after folding the flaps. FLEX BOX only folds and holds the bottom flaps, and the carton sealer tapes the top and bottom after filling. The carton erector stands at the start of the packing line, before the filling and sealing steps.

The erector opens the flat, folded blank into a square tube and closes the bottom; the top stays open for filling. Formed by hand, every carton means folding and taping the bottom flaps before the filling can start; an erector takes this step off the packing table.

On a packing line, the typical order is to erect the carton, fill it, close and tape the top, then label, strap or stack the carton on a pallet.

All three machines in this category work with standard cartons delivered flat, with the side joint already closed by the carton maker and four bottom flaps. The erector opens the flattened tube and closes the bottom, but it does not make the side joint.

How the bottom is closed shapes your packing line. A carton with a taped bottom from the AUTOBOX or AUTOBOX10 can move on a roller conveyor to a filling station further down the line, because the tape holds the flaps closed during transport. A carton from the FLEX BOX has its bottom flaps only folded and held, so you fill it while it stands on the machine and send it straight into the carton sealer after filling.

Automatic case erector models: AUTOBOX and AUTOBOX10

AUTOBOX takes its blanks from a sloping or horizontal worktable. Suction pulls one blank at a time into the machine, which opens it, folds the bottom flaps and tapes the bottom. It makes up to 16 cases a minute, depending on carton size. It has a Siemens PLC with a touch screen and is set to the carton size before the run. It uses BOPP or paper tape, 48 mm as standard.

AUTOBOX10 takes its blanks from a magazine with suction cups. It erects 10–15 cartons a minute. The touch screen offers automatic and manual modes and stores up to 10 carton sizes. A servo sets the carton width; the guides, belts and suction cups are set by hand. It tapes the bottom with 50 or 60 mm tape, 75 mm on request.

With AUTOBOX, you stack flat blanks on the worktable. The sloping worktable holds about 80 double-corrugated blanks, while the horizontal one holds about 150. If you use thinner board, you can fit more blanks in the stack.

It handles cartons 250–530 mm long and 150–400 mm wide. Tape heads for 60 or 72 mm tape are built to order.

AUTOBOX10 folds the front, rear and side flaps of the bottom, then tapes it. The machine pushes the erected carton out on its belts; its manual mode works step by step.

The carton size ranges of AUTOBOX and AUTOBOX10 overlap but are not identical. For example, a carton narrower than 200 mm fits only the AUTOBOX, which starts at 150 mm wide. A carton shorter than 250 mm fits only the AUTOBOX10, which starts at 200 mm long.

Both AUTOBOX and AUTOBOX10 run as long as there are blanks on the worktable or in the magazine. The operator’s job is to refill the blanks in time to keep the line moving. On AUTOBOX10, you can set a counter to stop the machine after a set number of cartons. For example, if you need to pack a fixed batch, the machine will stop automatically when the count is reached. Pressing Clear lets the machine continue for the next batch.

The AUTOBOX10 includes a manual debugging mode, where each press of the step button runs one step of the cycle: taking the carton, folding the front flap, folding the rear flap, folding the side flaps, pushing the carton out and resetting. There is also an ‘open a case’ function that erects a single carton. After a size change, you can use this function to erect one carton and check it before starting the automatic run. Check that its corners are square, the flaps are closed flat and the tape is centered.

On the AUTOBOX10, you enter the actual width of the carton for each stored carton number. When you select a carton number, the servo moves to that width. The conveying center point for this measurement is set at the factory and is not changed.

Compare box erectors by type, size and speed

The table below compares each box erector by type, carton size range, cartons a minute, how the blanks are fed and how the bottom is closed. Use it to check which machine fits your requirements.

To use the comparison table, start by checking the carton size range for each machine to see which fits your cartons. Next, look at the cartons a minute to match the machine’s speed to your packing rate. The last two columns show how the blanks are fed (by the operator, from a worktable or from a magazine) and whether the machine tapes the bottom or leaves taping to the carton sealer. The AUTOBOX and AUTOBOX10 rows are the machines that tape the bottom.

FLEX BOX semi-automatic case erector: operator and machine

With FLEX BOX, the operator takes a flat carton from the shelf, opens it and closes the front and rear bottom flaps as the carton is placed on the machine. Two air cylinders fold the left and right bottom flaps and hold the bottom closed while the operator fills the carton.

A push button or foot switch starts a pusher that sends the filled carton into a carton sealer, which tapes the top and bottom. FLEX BOX makes 6–7 cartons a minute with an operator at every carton. The worktable height is adjustable from 700 to 800 mm.

Once the carton is on the machine, it stands there while the operator fills it. The FLEX BOX serves as both the forming and filling station. After filling, the operator folds the top flaps by hand.

Match the worktable height to the carton sealer and to the operator. The carton length is set by moving the carton feeder with its adjustment knob. The product page names our semi-automatic carton sealer as the machine that works with the FLEX BOX.

The Match the worktable height to the carton sealer and to the operator. The carton length is set by moving the carton feeder with its adjustment knob. The product page names our semi-automatic carton sealer as the machine that works with the FLEX BOX.

The FLEX BOX is filled while the carton stands on the machine, so its output of 6–7 cartons a minute includes the time for opening, loading, filling, closing the top flaps and pushing the carton into the sealer. This means each carton takes about 9 to 10 seconds from start to finish. If the goods to be packed are not ready at hand, the output drops, as the next carton cannot be started until the filled one has left the machine.

The regulator on the air filter sets the speed of the pusher that moves the filled carton into the sealer. The pusher has to move the filled carton into the sealer firmly, but without a jolt that shifts the goods. Before work, the FLEX BOX must stand level on stable ground with its castors locked and the covers in place. If the machine stands crooked against the carton sealer, the pusher sends the carton in at an angle.

Carton sizes, tape widths and size changes

To choose the right machine, measure the smallest and largest carton you pack, including length, width and height. Compare these figures with the ranges: AUTOBOX handles cartons 250–530 mm long and 150–400 mm wide, while AUTOBOX10 covers 200–500 mm long, 200–400 mm wide and 150–350 mm high. For FLEX BOX, check the carton sizes on its product page.

For AUTOBOX10, you also need to check two sums: the length plus width must not exceed 900 mm, and half the width plus the height must not exceed 550 mm. Check both sums for your largest carton.

Tape choice is set with the order. AUTOBOX uses BOPP or paper tape, 48 mm as standard, with 60 or 72 mm tape heads built to order. AUTOBOX10 takes 50 or 60 mm tape, with 75 mm available on request.

A size change on AUTOBOX10 is done by selecting the stored carton number on the touch screen. The servo sets the width, and you set the guides, belts and suction cups by hand. Up to 10 carton sizes can be stored. AUTOBOX is set to the carton size before the run and can be built for other carton sizes if needed. Grouping orders by carton size reduces the number of size changes. Always check that the carton sealer after the erector can handle every size you run.

Always compare the size ranges to the erected carton, not the flat blank. The AUTOBOX10 manual asks you to confirm the size of the carton after it is formed before making any settings.

A size change on the AUTOBOX10 follows a fixed order: return the servo to zero, select the carton number, set the belts, adjust the magazine rails, set the carton bracket height, set the press guide plate height, adjust the forming positioning rods, set the forming bracket, adjust the suction cups and finally set the push rod. The suction cups come after the belts, rails, brackets and rods, because their position depends on those settings. When going from a larger to a smaller carton, move the suction cup holder down, as the press guide gets in its way. For a large carton, pull out the push rod without letting it touch the suction cup holder. None of the three machines sets itself to each carton. If you run mixed carton sizes in the same hour, each size change means a new setup.

Choosing a semi-automatic or automatic box erector

A semi-automatic box erector such as the FLEX BOX suits a lower output or frequent size changes, because the operator works at every carton.

An automatic box erector such as AUTOBOX or AUTOBOX10 forms and tapes each carton the same way, so the operator only refills the blanks. These models suit a steady flow of cartons. The filling step sets the pace of the line: if the box erector makes more cartons than can be filled, a queue builds up. All three models are adjustable to carton size within their range.

To match the machine to your needs, count the number of cartons you pack in the busiest hour and the number of people available for the task. Compare these figures with the speeds in the table.

Space is another factor. The AUTOBOX measures 3045 × 1855 × 1300 mm with the sloping worktable and 3045 × 2444 × 1300 mm with the horizontal one. AUTOBOX10 is 2020 × 2080 × 1396 mm. Leave room around the machine for loading blanks and for service access.

Work out the time per carton to check if your filling and sealing steps can keep up. On the AUTOBOX10, 10–15 cartons a minute means one carton every 4 to 6 seconds. This is the rate at which open, bottom-taped cartons will come out for filling.

With the FLEX BOX, one person opens, fills and sends each carton into the sealer. With the AUTOBOX or AUTOBOX10, erecting is separate from filling. You need to plan who will refill the blanks and where the open cartons will wait for filling.

An automatic erector needs someone who can set it up correctly. On the AUTOBOX10, a size change follows the set order of adjustments in its manual. The cylinder and air settings are for trained staff only.

Blanks, wear parts and box erector settings

A box erector needs flat, dry blanks. Warped or damp blanks are picked badly, open crooked or jam in the machine. Store blanks flat, dry and off the floor. Suction cups hold the blank by vacuum. Worn or dirty cups lose their grip; check them regularly on the AUTOBOX and AUTOBOX10.

On AUTOBOX10, the belts must just touch the sides of the erected carton. If too tight, the carton deforms. If too loose, it is not pushed out. The press plate should sit about 5 mm above the carton. If set wrong, the bottom tape can have a gap or the carton may not leave the machine. A dull blade on the tape head gives a ragged cut.

The maker of the AUTOBOX recommends keeping spare suction cups on hand.

If the main air regulator on AUTOBOX10 cannot hold its set pressure, the air supply is too weak and the suction pick-up fails. The blade and springs of the tape head are wear parts on the AUTOBOX.

On the AUTOBOX10, the magazine rails are set to leave a gap of about 5 mm between the flat carton and the side guide plate. This gap lets the carton slide easily when picked by the suction cups. Rails set too tight hold the carton back in the magazine.

The AUTOBOX10 picks up the carton on its wider side, with the outer edge of each suction cup about 15–20 mm from the carton edge. Set them after the magazine rails, brackets and positioning rods, otherwise the pick-up fails.

The forming bracket on the AUTOBOX10 is set to the carton length. If it is set wrong, the carton can come out deformed, diamond-shaped, damaged or stuck in the machine. Always check that the erected carton is square before starting the run. The thickness of the board also affects how the carton forms. The knobs on the cylinders set their push and return speed, but these are for trained staff and only after the forming positions and carton sensors are set. The AUTOBOX is delivered with a spare blade, spare tape-head springs, screws and hand tools, so you can replace the first blade or spring without waiting for parts.

What decides the price of a box erector

The price of a box erector depends on whether it is semi-automatic or automatic, if it tapes the bottom, the type of worktable, tape heads and carton sizes built to order. Running costs include tape, compressed air and wear parts such as suction cups, the blade and springs of the tape head, and the belt.

FLEX BOX uses no tape itself, as taping is done by the carton sealer after filling. The product cards have a Get offer button for a quote, such as for an erector together with a carton sealer, and an Add to inquiry button to collect several products into one request.

On the AUTOBOX, a higher worktable or blanks fed in from the left instead of the right are built to order. If you need either, include it in the same inquiry as the machine.

With the FLEX BOX, a carton sealer placed right after it is part of the set, since the bottom is taped only at that stage. With the AUTOBOX or AUTOBOX10, the top can be closed by a carton sealer you already have, as long as it takes the same carton sizes. Wear parts on the AUTOBOX go beyond the suction cups and tape head: its maker’s list also includes the vacuum generator, cylinders, linear bearings and valves.

Compressed air, power and safe work with box erectors

All three box erectors need compressed air and power. FLEX BOX runs on 220 V, 50 Hz, 600 W. AUTOBOX uses 220 V single phase, 50/60 Hz, 400 W. The air unit needs care: drain water from the air filter regularly. Switch off the power and the air before any work on a box erector. No loose sleeves, ties, rings or watches at a machine with belts and moving arms.

AUTOBOX10 starts its automatic cycle only after the servo has returned to zero and the cylinders are at their start position. FLEX BOX shuts down if the control panel is opened while it runs. The bottom drive chain on FLEX BOX is lubricated once a week and bolts and screws are checked regularly.

FLEX BOX uses compressed air for the flap cylinders and the pusher, AUTOBOX and AUTOBOX10 for their cylinders and the suction pick-up. Plan an air line to the packing place.

The AUTOBOX10 stops by itself when the carton counter reaches the set number. Pressing Clear lets it continue. Its pneumatic valve settings are for trained staff only.

AUTOBOX10 maintenance includes cleaning, lubricating moving parts, checking air pressure and inspecting suction cups and belts for wear.

On the AUTOBOX, the vacuum for the suction cups comes from a vacuum generator that runs on compressed air. If the air supply is weak, you will see cartons not being picked, as the AUTOBOX10 manual also warns.

The AUTOBOX has IP54 electrical protection, which means it is protected against dust and splashing water. Its noise level is up to 75 dB.

Before any adjustment on the AUTOBOX10, switch off the power, disconnect the air and clear everything from on, under and around the machine. If a person is caught by a moving part such as a belt, switch off the power first, then free the person. The FLEX BOX is plugged into a socket, not wired in. Its power switch is off before it is connected, and the emergency switch is checked when the air is connected. The AUTOBOX10 position teaching screen is behind a login. Keep the login with the person in charge.

Checklist before ordering a box erector

Before ordering a box erector, check the carton sizes: length, width, height, smallest and largest. Know the number of cartons an hour at the peak, how many sizes you run and how often they change. Check the tape width you use, the compressed air and power at the packing place, and the space for the machine.

Decide the direction of flow and the height of tables and conveyors. The carton sealer after the box erector must take the same carton sizes. A roller conveyor between the box erector, the filling place and the carton sealer carries the open cartons. These points help match the machine to your packing line.

Count the number of cartons you need to pack per hour at peak times. Decide if you want an operator at the machine, as with FLEX BOX, or if you need an automatic erector like AUTOBOX or AUTOBOX10.

Mind the direction of flow. AUTOBOX takes blanks in on the right and sends cartons out on the left as standard. The opposite direction can be built to order.

Match the heights of your equipment: FLEX BOX worktable is adjustable from 700 to 800 mm, AUTOBOX is 650 mm as standard and up to 1000 mm built to order, AUTOBOX10 is 650 mm. Choose the tape width with the order. The AUTOBOX is specified for -10 to 40 °C and humidity up to 98 percent, so check if your dispatch area stays within these limits.

If your new machine will work with a carton sealer you already have, include that sealer’s model and working height in your inquiry. The carton sizes and the heights can then be checked against both machines.

Questions about box erectors

Which box erectors tape the bottom of the carton?

AUTOBOX and AUTOBOX10 both tape the bottom of the carton after folding the flaps. FLEX BOX does not tape the bottom; it only folds and holds the flaps.

Do these box erectors need compressed air?

All three box erectors in this category require compressed air to operate. This is needed for functions such as suction, folding flaps or driving the pusher.

How many cartons a minute can each box erector make?

FLEX BOX makes 6–7 cartons a minute with an operator. AUTOBOX10 makes 10–15 cartons a minute. AUTOBOX makes up to 16 cases a minute, depending on the carton size.

Can one box erector handle different carton sizes?

Yes, each box erector can be set to different carton sizes within its range. AUTOBOX10 stores up to 10 carton sizes and uses a servo to set the width. AUTOBOX is set to the carton size before the run. FLEX BOX is adjustable to the carton size.