Chips Packaging Line For USA Customer

A customer, a snack brand in the American market, has a requirement to package 6 flavors of bagged chips through an integrated, multi-stage system that moves from retail-ready display packaging to palletized shipping units. The customer is seeking a turnkey solution to mitigate labor constraints and ensure consistent, high-speed throughput. The equipment they are planning to purchase:

• Carton erector machine (glue).
• Carton sealer machine (glue).Speed: 20-30/ minute
• Case erector (tape)
• Case packer (8 cartons in 1 case)
• Case sealer (tape)
• Case palletizer

The core of the specification lies in a folding carton packaging system using 460gsm paperboard—a material chosen for its balance of print quality and structural integrity for retail presentation. This is a classic paperboard folding carton application where the packaging must transition from a flat, shippable blank to a finished display box holding a precise mix of flavors chips counts: 4/3/2/4/3/2 bags per carton, carton have two sizes: 1）L197*W356*H146mm 2）L197*W394*H146mm.

The scope extends to secondary packaging, where these retail cartons must be collated into 2×4 arrangements and loaded into shipping cases. The case also have two sizes: 1）L610*W413*H407mm 2）L610*W413*H356mm.

Finally, the finished cases require an automated robotic case palletizer for efficient stacking, optimizing warehouse space and logistics. Pallet size: 1219 × 1016 mm. Stacking: 5 cases/layer × 6 layers.

Our Packaging Solution

Our proposal delivers a complete, integrated end-of-line packaging system engineered to meet the specific speed, format, and output requirements of this U.S.-based customer. We offer a synchronized line designed for maximum efficiency, employing a combination of high-speed primary packaging machinery, flexible secondary case packing, and intelligent robotic automation.

Stage 1: Primary Packaging – Carton Erection, Loading, and Sealing

The line begins with the Automatic Carton Erector and Bottom Sealer (Glue). This machine is the entry point for the 460gsm paperboard blanks. It utilizes a high-capacity magazine storing up to 100 flat cartons, which are individually picked via suction cups and formed into a three-dimensional box. The machine automatically folds the bottom flaps and seals them using a hot melt glue system to ensure a strong, clean finish suitable for retail display . Its speed is precisely matched to the customer’s demand, achieving 20 cartons per minute (within the 20-30/min spec).

After erection, the line offers flexibility for manual or automatic carton loading. For future scalability, we propose an optional Robotic Carton Packing cell featuring a collaborative robot (cobot) to pick and place the six flavors of bagged chips into the moving cartons. This top-load case packer ensures precision and hygiene, accommodating both the 4/3/2 count configurations effortlessly. Following filling, the Carton Sealer (Glue) completes the primary process. This machine automatically closes the top flaps of the filled cartons and applies glue to secure them, ensuring a tight, aesthetically pleasing seal at 20 cartons/min.

Stage 2: Secondary Packaging – Case Erection, Packing, and Sealing

Transitioning to the secondary line, the Case Erector (Tape) forms corrugated shipping cases from flat blanks. This automatic case erector and sealer uses suction cups to open the case and applies a single strip of pressure-sensitive tape to form the bottom, ready to receive product at a speed of up to 20 cases per minute.

Next, our Case Packer handles the collation and loading. This machine systematically arranges the finished retail cartons into the required 2×4 format (8 cartons per case). The system is designed to operate in either manual or fully automatic mode, with robotic case packing providing a significant boost in consistency and labor savings for high-volume runs. The packer’s design is adaptable to feed both sizes of shipping cases, ensuring continuous flow.

Finally, the Case Sealer (Tape) is positioned at the end of the line. This robust machine automatically folds the top flaps of the filled shipping cases and seals them with industrial-grade tape, completing the packaging process at speeds exceeding 25 cases per minute. Its adjustable taping heads and top/bottom drive belts handle the various case sizes without the need for extensive manual adjustment.

Stage 3: Palletizing – Robotic Automation

The final stage is the Robotic Case Palletizer. This system is the cornerstone of modern end-of-line automation, capable of handling the repetitive, heavy lifting required to stack cases onto pallets. Our case palletizer is equipped with a high-payload articulated robot arm that provides precise, fast stacking and pattern formation. Programmable for multiple SKUs, it manages the flow from the two different case sizes, stacking them onto pallets according to pre-determined patterns to maximize stability and shipping density. With an automation platform capable of replacing up to ten operators per shift and reducing payback periods, this solution not only eliminates manual palletizing bottlenecks but also enhances workplace safety and ensures consistent, reliable output, ready for warehousing or direct shipping.

Finally, let me quickly summarize what our packaging line includes.
1)One set of carton erector and bottom sealer.
2)Three units of curve/bend conveyor.
3)Positioning slat chain conveyor with a total length of 13,000mm, made as two separate units.
4) If automatic carton loading: 6 sets of robotic pick-and-place units, which arrange pouches into carton-filling quantities based on each station’s requirement. For example, Station 1 fills 4 pouches per carton, and Station 2 fills 2 pouches per carton.
5)One set of slat chain conveyor with a length of 3,000mm.
6)One set of carton sealer, including a conveyor for manual carton loading.
7)Two sets of hot melt glue machines (with two hoses and two guns).
8)One set of case erector.
9)One set of case packer.
10)One set of case sealer.
11)One set of positioning conveyor.
12)One set of assisting robot palletizer.