Automatic Case Packer

Our secondary packaging automation systems are engineered for maximum versatility across pharmaceuticals, food, and daily chemicals. By switching modular End-of-Arm Tooling (EoAT), a single base machine can seamlessly handle:
• Carton & Box Series: Alu-plastic blister cards, small folded cartons, and medical injection trays.
• Bottle & Can Series: PET bottles, glass containers, metal cans, and vials.
• Flexible Pouches & Bags: Stand-up pouches (DOYPACK), gusseted pillow bags, and pre-made composite pouches.
• Customized Configurations: Milk tea cups, jelly cups, protective film rolls, and bulk tubs.

We provide highly flexible, custom configurations to eliminate production line bottlenecks. The standard dimensional footprints of our core catalog are configured as follows:
• Case Dimensions (Top-Load Series - ZY-CP400 / ZCP-500): Supports outer shipping case sizes ranging from 250 × 200 × 200 mm up to 600 × 400 × 300 mm.
• Heavy-Duty Case Series (All-in-One Form-Pack-Seal - ZCP-600): Accommodates heavy shippers up to 100 kg, with maximum case dimensions up to 600 × 500 × 500 mm.
• Primary Packaging Items (Infeed Collator Specifications): Adapts to single-unit units with lengths of L ≤ 180 mm and widths of W ≤ 100 mm.
📐 Custom Engineering: Leveraging our extensive CNC smart manufacturing capabilities and independent R&D center, our design engineers can modify the mechanical limits and stroke lengths in our 3D CAD models to match your unique case requirements.

Our changeover processes are highly optimized to maximize your Overall Equipment Effectiveness (OEE):
• Single Module Adjustment: For our automatic case erector (KX-550) and standalone modules, changeover takes approximately 1 minute using manual handwheels paired with visual digital position indicators.
• Full Line System Switch: For a complete "Erect-Pack-Seal" system, the transition takes less than 15 minutes and is completely tool-less. Operators simply select the recipe parameters on the HMI touchscreen, and the system automatically recalibrates our multi-servo motion control vectors to align the guide rails perfectly.

Yes. We specialize in solving complex, non-standard collating and matrix packaging configurations. For retail-ready displays or structurally unstable products, we deploy independent servo-driven rotation units and sorting platforms.
• Application Example: For high-speed jelly cup production lines, we integrate a dedicated matrix collation system that executes alternating interlocking patterns (front-to-back nesting) prior to the pick-and-place cycle, ensuring highly secure and dense case utilization.

Absolutely. Depending on your factory floor layout and production throughput goals, we offer multiple flexible configurations:
• Side-Push Integration: Ideal for cartoned pharmaceutical lines where dual-servo pushers slide collated product matrices horizontally into the case.
• Robotic Pick-and-Place (Top-Loading): Utilizes multi-axis ABB, KUKA, or Delta/Spider high-speed robots to grab flexible pouches, blisters, or loose bottles and place them vertically or horizontally into the shipper.

Our equipment is uniquely engineered to process a wide range of standard and recycled corrugated cardboards without compromising your secondary production line uptime.
The magazine of our automatic case erector (KX-550) holds approximately 100 blanks simultaneously. It uses a dual-sided servo vacuum extraction mechanism to force open warped or highly rigid cartons at a perfect 90° angle. Concurrently, independent squaring devices firmly clamp the case chassis before any side-push loading begins, completely eliminating feed jams.

To meet strict cleanroom and cleanliness standards in electronic and pharmaceutical packaging environments, our machinery integrates a multi-layered mitigation framework:
• Dust & Debris Control: Our high-speed dual-channel collators (BHLD-500) and corrugated magazines are built with fully enclosed 304 stainless steel frames to isolate and minimize airborne dust generation.
• Self-Cleaning Vacuum Channels: The high-flow pneumatic systems (SMC or FESTO) are equipped with automated inline blast purge valves. Each time a case blank or pouch is picked, a high-pressure air burst clears paper fibers and dust from the suction cup faces, ensuring consistent vacuum grip thresholds.

Our technology platform is natively compatible with both sealing methods and supports advanced environmental customizations:
• Tape Sealing: Compatible with standard 38mm or 50mm OPP/Kraft tapes, featuring fully adjustable tensioning mechanisms.
• Hot Melt Glue: Easily integrates premium OEM hot melt systems (such as Nordson) for high-speed, tamper-evident, and structurally secure closures.
• Explosion-Proof Customization: For automated aerosol, chemical, or volatile solvent filling lines, we engineer specialized monoblock systems (SZP-500 Explosion-Proof Variant) equipped with isolated, purged electrical enclosures and intrinsically safe pneumatic components.

We deploy an active matrix monitoring grid to achieve zero-hollow-case and missing-unit protection. The system tracks the complete packaging cycle through advanced photoelectric array sensors installed at every critical station:
[Infeed Product Check] ➡️ [Missing Unit Blind Check] ➡️ [Overload Jam Sensing] ➡️ [Case Alignment Check] ➡️ [Downstream Reject Gate]
If the multi-servo collation system detects a missing bag or incorrect box layout, the machine executes a controlled pause. The case remains open and will only resume cycle once the count is verified as correct. Downstream lines can be seamlessly paired with our integrated checkweigher and vision inspection systems to automatically eject under-filled cases.

We manage all pick-and-place profiles via absolute servo motor trajectory curves, completely eliminating the abrupt mechanical shocks associated with older, pneumatic-driven pushers.
Whether handling delicate pharmaceutical blister packs or luxury cosmetics glass bottles, the robotic arms follow controlled acceleration/deceleration profiles, automatically dampening into a slow crawl speed millimeters before making contact with the product or the bottom of the case. Furthermore, all EoAT are equipped with custom padded silicone suction cups or soft-touch non-marking mechanical grippers.

All of our standard and customized machines are engineered to minimize floor footprint while maximizing access space:
• Compact Monoblock (Side-Push Case Packer ZY-CP450): Requires a footprint of just 2400 × 1200 × 1900 mm.
• High-Speed Robotic Loader (ZCP-600): Dimensions span approximately 4200 × 2660 × 2200 mm with an adjustable conveyor working height of 850 ± 50 mm.
• Flexible Line Configuration: Our plant layout designs are highly flexible. We can configure the packaging line in In-line (straight), L-shape (90-degree turn), or U-shape (reverse turn for single-operator oversight) layouts to seamlessly route around structural pillars or narrow walkways.

Our systems feature an open, highly communicable control architecture capable of handling upstream and downstream signals smoothly. The layout is driven by standard intelligent controllers and communicates via common industrial networks such as EtherCAT or EtherNet/IP. This creates an interconnected data loop that synchronizes perfectly with your main plant machinery:
Upstream Cartoner/Filler ➡️ URMACHINE Smart Case Packer ➡️ Downstream Palletizer
If the upstream cartoner or liquid filler slows down, our multi-servo collation loader automatically throttles its speed to match incoming product flow. If a downstream stretch wrapper, strapper, or palletizer stops, our machine enters a controlled pause state, preventing conveyor back-ups and product crushing.

Yes. Our engineering team frequently designs integrated mounting brackets within the main chassis and establishes software handshake protocols for major third-party print/scan hardware.
For instance, our Print-and-Apply Labeling System (JD-50) can be integrated directly onto the outfeed sealing guide rails. This allows real-time printing of text, variable lot dates, barcodes, and QR codes on the top or side of the case at speeds up to 50 cases/minute, without requiring an external standalone conveyor extension.

Our continuous automated packaging lines are structured into precise performance tiers to match your volume requirements:

• ZY-CP400 (Top-Load Case Packing Line): Rated at 1 - 6 cases/minute (240 cases/hour). Best suited for pharmaceutical cartons, bottles, and bulk bags.
• ZCP-500 (Integrated Form-Pack-Seal System): Rated up to ≤ 16 cases/minute. Designed for high-speed secondary case packaging lines.
• BHLD-500 (Dual-Channel High-Speed Collator): Processes up to 500 bags/minute. Engineered for high-speed pouch sorting, grouping, and continuous nesting.
• ZH-450 (Ultra High-Speed Cartoner): Operates at up to 450 cartons/minute. Engineered for maximum output in pharmaceutical blister lines.

Our equipment is engineered from the ground up to ensure low maintenance overhead and high OEE metrics:
• Daily Tasks (< 5 minutes): Visually check main pneumatic pressure gauges (maintain ≥ 0.5 - 0.6 MPa), inspect vacuum suction cups for wear, and wipe clean any loose cardboard dust from the working stations.
• Weekly Tasks: Verify the status of the automated central lubrication lines and inspect tape/glue reservoir levels.
• Smart Scheduling: The interactive HMI features a built-in preventative maintenance tracking utility that displays running hours and triggers visual pop-up reminders when components require greasing or routine checkups.

Our standard configurations utilize globally recognized, premium component brands to guarantee international availability, high reliability, and seamless spare parts sourcing:
• Logic Controllers & HMI: Siemens / Omron / Rockwell Automation
• Pneumatics & Drive Actuators: SMC / FESTO / SEW-Eurodrive
• Safety Controllers & Light Curtains: Sick / Omron

💡 If your plant enforces a strict component standardization policy, we can fully customize and adapt the Bill of Materials (BOM) during the initial contract engineering phase to match your preferred vendors.

Operator safety is the absolute priority of our engineering designs. All of our automated platforms are constructed to comply strictly with CE, OSHA, and pharmaceutical GMP compliance standards:
• Heavy-Duty Guarding: Features a high-rigidity aluminum alloy and stainless steel frame structure lined with high-impact, shatterproof transparent viewing panels.
• Category 4 Safety Interlocks: Every access door is equipped with dual-channel safety switches. Opening any guard door immediately vents main pneumatic pressure and cuts power to all servo-driven axes in milliseconds to prevent injury.
• Emergency Stop Array: Highly visible E-Stop buttons are strategically positioned on all four corners of the machine frame, ensuring immediate shutdown capability from any side.

Yes. To minimize unplanned downtime, our main control cabinets can be equipped with cloud-encrypted Industrial IoT VPN routers (such as Ewon).
With explicit permission and remote access activation from your local floor team, our technical support engineers can securely log directly into the machine's PLC. We can diagnose sensor alignments, analyze fault codes, and upload immediate software optimizations. This remote methodology successfully resolves over 85% of minor configuration issues within 30 minutes, eliminating the need to wait for on-site field service travel.

• First-Year Support Kit: Every automatic case packer ships with a complimentary first-year critical wear package containing essential components (such as extra vacuum cups, heating elements, cutting blades, and proximity sensors).
• Rapid Logistics Network: We maintain a comprehensive parts inventory at our centralized manufacturing hub and regional distribution nodes to support rapid, same-day dispatch for critical maintenance needs.
• Non-Proprietary Standards: Because our systems utilize non-proprietary global component standards (e.g., SMC, FESTO, and Omron), basic replacement parts can be easily cross-referenced and sourced directly from your local local industrial distributor.

We provide a comprehensive, full-lifecycle deployment workflow to guarantee smooth integration onto your production floor:
1. Product Analysis & Solution Stage: We gather actual samples of your pouches, boxes, or bottles to execute precise 3D CAD modeling, optimizing the infeed path and customized machine orientation.
2. Factory Acceptance Testing (FAT): Prior to shipping, we execute rigorous full-load testing at our facility using your actual product batches and cases to verify throughput speeds and matrix accuracy thresholds.
3. Site Acceptance Testing (SAT): Our field service engineers handle the physical machine leveling, anchoring, signal handshakes with up/downstream equipment, and final line sign-off.
4. Technical Training Program: We provide a structured 3-day training course for your operators (covering HMI operation, recipe calls, and rapid changeover) and maintenance teams (covering mechanical calibration, preventative intervals, and diagnostics), complete with digital manuals and video guides.