Is Your Box Design Ready for Automation?
When switching from manual to automated cartoning, one of the most critical success factors is the design of your boxes. What works perfectly for human hands can often cause a machine to jam. A recent collaboration with a client, who packages metal tins in snap interlocking bottom boxes, perfectly illustrates this point.
The client’s initial box design was functionally sound for hand-packing. However, for our cartoning machine to reliably form, tuck, and lock the bottom flaps, a few subtle modifications were essential:
- The protruding tabs on both the major and minor side flaps need to be trimmed. The two side flaps had small protrusions. These would catch during the machine’s folding sequence. We recommended trimming them to create a clean edge for smooth entry into the folding path.
2.The leading edge of the minor flap should be slightly beveled instead of being a straight cut. The straight edge of the base flap risked snagging. A slight bevel or angle was introduced, allowing the machine’s pusher to guide it seamlessly into place.
3.The major flap is too long and needs to be shortened to avoid collision during the closing sequence. The face flap was simply too long. Shortening it ensured a clear path for the folding mechanisms to interlock the flaps without collision.
These minor tweaks weren’t about re-inventing the box, but about optimizing it for machine precision. Unlike human fingers that can adapt to slight variations, a cartoning machine relies on consistent, predictable geometries to perform at high speeds.
The most efficient automated packaging line starts with a box designed for automation. Consulting with our engineering team early in your packaging design phase ensures your interlock bottom boxes are not just beautiful, but also machine-friendly. This collaboration guarantees flawless performance, maximizes your line’s uptime, and unlocks the full ROI of your automation investment.
