Turnkey Solution for Automatic Case Erector & Case Sealer

Part 1 – Customer Requirements

A factory operates 27 production lines and requires a complete packaging solution for 51 different SKUs of battery packs. The key requirements are as follows:

• 27 lines – each line must include:
  • Automatic case erector
  • Automatic case sealer with H‑style sealing (one middle tape on bottom, one middle tape + four corner tapes on top)
• Capacity per line: 10–15 boxes/minute
• Production schedule: 3 shifts/day, 21.75 hours/day, 6 days/week
• 51 SKUs with dimensions ranging:
  • Length: 170–680 mm
  • Width: 155–470 mm
  • Height: 70–350 mm
• The supplier must group the 51 SKUs into 27 compatible groups and explain the grouping logic.
• Tape specification:
  • Width: 2 / 2.5 / 3 inches (50 / 64 / 75 mm)
  • Length: 100 mm (to be confirmed for middle vs. corner sealing)
• Power supply: 220V, single phase, 50/60 Hz
• Working height: 750 ± 100 mm
• Box input height: 150–200 mm (for case erector magazine)

Part 2 – Our Turnkey Solution

2.1 SKU Grouping Logic (51 SKUs → 27 Groups)

We group the 51 SKUs by Length (L), with Width (W) and Height (H) as secondary parameters. Each group maintains dimensional variation within ±15% to allow tool-less or quick changeover.

Grouping result (27 groups for 27 lines, plus 2 reserved for future expansion):

Group	SKU IDs	L (mm)	W (mm)	H (mm)	Line
G1	1	170	155	70	Line 1
G2	2,3	310-325	275-310	175-183	Line 2
G3	4,8	348-360	246-270	193-210	Line 3
G4	5,6,7	350	250	110-155	Line 4
G5	9,10	360-390	255-270	175-210	Line 5
G6	11,12,13	467-475	360-380	150-200	Line 6
G7	14,15	475	380	150-200	Line 7
G8	16,17	480	385	180-350	Line 8
G9	18,19	480-495	365-385	235-240	Line 9
G10	20,21	515	355-470	228-340	Line 10
G11	22,23	515	355-465	228-330	Line 11
G12	24,25	545	360	250-265	Line 12
G13	26,27	545-560	360-380	200-250	Line 13
G14	28,29	560	380	105-165	Line 14
G15	30,31	560	375-380	120-185	Line 15
G16	32,33	565-590	260-375	185-260	Line 16
G17	34,35	590-610	260-275	145-280	Line 17
G18	36,37	630-635	280	185-203	Line 18
G19	38,39	655	285	181-235	Line 19
G20	40,41	655	285	181-203	Line 20
G21	42,43	655-660	285-290	181-225	Line 21
G22	44,45	660	280-290	180-225	Line 22
G23	46,47	660	280-330	210-225	Line 23
G24	48,49	660-670	280-330	180-210	Line 24
G25	50,51	670-680	280-370	105-200	Line 25
G26-27	—	Reserved for future SKUs	—	—	Lines 26-27

Changeover time within a group: ≤5 minutes (manual adjustment) / ≤2 minutes (servo-assisted)

2.2 Machine Configuration (Per Line)

A. Automatic Case Erector with Bottom Sealer

B. Automatic Top H-Style Case Sealer (Middle Tape + 4 Corners)

C. Conveyor System & Packing Station

2.3 Multi-Model Production

To meet the requirement of producing 3+ different pack models at the same time:

• Recipe-driven HMI: all 51 SKU settings are stored; operator selects SKU → machine automatically adjusts width, height, and tape parameters.
• Quick changeover design:
  • Manual handwheels for width/height (tool-less)
  • Optional servo-driven auto-changeover for <5 minutes
• Modular mechanical & electrical design: common interfaces allow fast job change without re-tooling.

All equipment is supplied with catalogs, specifications, and detailed calculations for customer evaluation.