Carton Forming Machine: The Complete Buying Guide in 2024

1.How To Define Carton Forming Machine?

Carton Forming Machine

A carton forming machine also called a carton erecter or a carton former is a machine that takes blank chipboard, cardboard, corrugated banks or paperboard and erects, folds, and seals it into a carton. Its primary function is to form cartons that are with or without upper covering.

It is a servo-driven machine that forms and seals cartons using a lock mechanism. It also seals cartons with glue, tape, or adhesive. It is designed for achieving high speed, is versatile in its processing and easily handles a complete range of blanks. It is seamlessly integrated into the packaging line for streamlined operation.

2.What are the Useful Benefits of Carton Forming Machine?

Carton forming is added to the production because of its adaptability and fast processing. Some of the important benefits of this machine are:

Automation

Automation of Carton Forming Machine- Picture Courtesy: Fipal Srl

A carton forming machine is composed of different mechanical and computerized systems that automate the process of forming a carton. With its automation, it can make numerous cartons per minute. Automation of the carton forming machine translates to high productivity that is related to more profits.

Cost-Cutting

Cost cutting with Carton Forming Machine

With its automation, it also cuts down the need for human intervention and manual labour. This in turn lowers the labor wages saving operation costs. Moreover, with this machine, there is less chance of material wastage which leads to reduced material purchase and saves the packaging budget.

Consistent Performance

Consistent Performance of Carton Forming Machine- Picture Courtesy: SiroSilo Industrial

Carton forming machine has no variation from batch to batch and each time it produces cartons of the same size, design, and, dimensions. These cartons do not have even a minute difference in their structural composition and that leads to consistency in the secondary packaging. This uniform quality of cartons is vital in protecting the goods and in upholding a professional look.

Customization

Customization of Carton Forming Machine- Picture Courtesy: Pixartprinting

A carton forming machine is a flexible and versatile machine that is easily customized to create different carton types according to production packaging requirements. This machine is tailored to fabricate a wide range of cartons with easy and quick adjustments to machine parts. This versatility of the carton forming machine is important for businesses producing multiple cartons.

Increased Safety

Safety Emergency Stop Button- Picture Courtesy: Quisure

Fulfilling industrial safety guidelines is a must for manufacturing lines to prevent workplace accidents. A carton forming machine has different features like fireproof electric cabinets, safety enclosures, alarm systems, buzzers, and safety stop buttons for the safety of the operator and the workplace.

3.Where Carton Forming Machine is Used?

A carton forming machine is used in every far and wide industry because of its accurate and precise working and adaptability. Here is a list of some important industries in which a carton forming machine is utilized:

Food Industry

Use of Carton Forming Machine in Food Industry- Picture Courtesy: Pixartprinting

In the food industry, different types of boxes and trays are used for secondary packaging of food pouches, bags, clamshells, bottles, jars, and tins. It also creates trays and boxes for packaging fast foods and ready-made meals.

Beverage Industry

Use of Carton Forming Machine in Beverage Industry- Picture Courtesy: Packaging Strategies

A carton forming machine has a significant contribution to the beverage industry as it creates cartons for storing various sodas, juices, oils, smoothies, drink mixes, alcoholic beverages, water, and many more. Its seamless processivity is what makes it important in the beverage industry.

Pharmaceutical Industry

Use of Carton Forming Machine in Pharmaceutical Industry- Picture Courtesy: CPHI Online

A carton forming machine has a prime place in the pharmaceutical industry for packing blisters, syringes, ampoules, vials, etc. This machine fabricates different carton types like external flap cartons, trays, regular slotted cartons, and many more in the pharmaceutical industry.

Cosmetic Industry

Use of Carton Forming Machine in Cosmetic Industry- Picture Courtesy: Sufio

Due to its knack for creating beautiful and captivating cosmetic cartons, this machine has prominence in the cosmetic industry. It creates secondary packaging cartons for cosmetic lotion bottles, foundation tubes, cream jars, lipsticks, and many more.

Chemical Industry

Use of Carton Forming Machine in Chemical Industry- Picture Courtesy: Storemasta Blog

Chemical products need sturdy and leakproof packaging for their containment and hence, carton forming machine is a vital part of the chemical industry. It creates strong and durable cartons for shipping and retailing chemicals.

Textile Industry

Use of Carton Forming Machine in Textile Industry- Picture Courtesy: Canpak Packaging

Different cloths, fabrics, threads, and fashion accessories are transported in tough and strong cartons. Therefore, carton forming machine is utilized in the textile industry for erecting and forming robust containers that can easily handle heavier textile loads.

Electronic Industry

Use of Carton Forming Machine in Electronic Industry- Picture Courtesy: NetPak

This machine is needed in the electronic industry for packaging different flashlights, equipment, bulbs, fans, etc. in tough and durable boxes. This machine is a high-speed instrument used for the correct packaging of electronic goods.

4.What are the Primary Parts of a Carton Forming Machine?

Various parts of the carton forming machine carry out their specific role in harmony to ensure the steady performance of the carton forming machine. these parts are discussed below for your understanding:

Parts of Carton Forming Machine- Picture Courtesy: SiroSilo Industrial

Vacuum Sucker	This part of the carton forming machine picks up the blank carton sheet from the blank magazine using suction force and holds them without damaging these sheets during succeeding carton forming steps.
Press Plate Height Adjustment	It consists of screws and knobs that assist in adjusting the height of the press plate. It is a mechanism that helps deliver accurate pressure force to the flaps of the carton.
Blank Retainer	During the folding and gluing step, the blank retainer parts grip securely the blank sheets using clamps and rollers. It is essential in the precise folding of sheets and the application of glue to carton sides. It is composed of clamps, rollers, etc.
Touch Screen HMI	It is an intuitive display panel that is present in most carton forming machines. Using this HMI touch screen, the operator programs and supervises the equipment. Furthermore, it outputs troubleshooting instructions in case of machine failure.
Protective Glass	It is a clear glass cover surrounding the machine that prevents operators from unintentionally gaining access to the carton forming machine.
Power Switch	This is the main switch for powering the carton forming machine.
Case Height Adjustment	It is a system that fix the height of the forming section to accommodate cartons of different sizes and designs.
Press Plate	It is used for applying pressure to the carton sides to create a strong bond between them. It is present above the side belt part and is vital in giving the carton box its shape.
Blank Magazine	This is the part where large quantities of cardboard or other material sheets are placed before the operation.
Air inlet	It is an inlet through which compressed air enters the carton forming machine and is rudimentary in working vacuum sucker.
Side Belt Width Adjustment	This part of the carton forming machine adjusts the width of side belts which allows for an accurate transport of blanks to the forming station.
Electric Cabinet	Different kinds of switches, relays, power cables, and small wires are enclosed in the durable electric cabinet. This section of the machine is essential in powering its different components.
Emergency Stop	It is a red-colored knob present on the control panel. It is pressed to instantly stop the machine in case of a hazardous situation.
Foot Pad	It is a foot support that absorbs any shock or vibration that occurs while the machine is in operation. It supports and stabilizes the carton forming machine.
Side Belt	It is the part that transports the blank sheets to the forming machine. It is essential in the proper alignment of the cardboard sheets.

5.What are Different Kinds of Carton Forming Machines?

A carton forming machine is classified into different types depending on the automation and carton styles. Here is a detail of the classification of a carton forming machine.

According to Automation

Semi-automatic Carton Forming Machine

Semi-automatic Carton Forming Machine- Picture Courtesy: Fallsdell

It is a compact-sized machine that carries out its functioning with the help of an operator. The blank cardboard or other materials are manually loaded on the blank magazine. Forming, pressing, and gluing are performed independently by the machine.

Its productivity is low; hence, it is best suited for small-scale operations. It is quite budget-friendly so preferred choice for small enterprises.

Automatic Carton Forming Machine

High Speed Automatic Carton Forming Machine

 It comes with an integrated blank magazine and sometimes robotic systems that automatically lift and load the blank magazine. Forming, pressing, and unloading are carried out autonomously by the machine with its mechanical and computerized controls.

It has higher productivity; therefore, more suited to larger businesses. It requires a high initial investment and a larger operating room.

According to Box Type

Regular Slotted Carton Forming Machine

Regular Slotted Carton Forming Machine

It is the most frequently used carton forming machine because it outputs a popular box style which is a regular slotted carton. Regular slotted carton forming machine forms cartons from a single blank that has prescored flaps.

The working of this machine is straightforward and it is easy to operate. However, it does not accommodate intricate box shapes.

Tray Carton Forming Machine

Tray Carton Forming Machine- Picture Courtesy: Wayne Automation

This machine folds and prepares a tray-like box that does not have an upper lid. This tray is used for the delivery of pre-made meals. It is a versatile machine that is capable of creating all kinds of standard tray boxes.

It is not suited for creating closed boxes.

Tuck Top Carton Forming Machine

Tuck Top Carton Forming Machine- Picture Courtesy: SiroSilo Industrial

It folds and creates a top tuck carton using pre-folded top sides. It is a cost-effective machine because it does not use tape or glue to close the box. It creates secure closure boxes that are ideal for faster packaging of products.

Nevertheless, this machine requires specialized parts for forming tuck-top cartons.

6.What is the Working Principle of Carton Forming Machine?

Steps of carton Forming Machine

The working of the carton forming machine is divided into different steps, and each is carried out flawlessly to convert blanks into cartons. The details of these steps are given below:

Blank Loading

Blank Loading

Initially, a large stack of flat sheets is loaded inside the bag magazine by the operator or by the robotic arm. It is stored in the loading area or bag magazine for continuous carton forming.

Vacuum Sucking and Alignment

Vacuum Sucking and Alignment

Sheets are positioned in the right orientation by the vacuum sucker. This part of the carton forming machine picks up the blank and carries it to the forming station. It creates a suction force by which blanks move to subsequent processing stations.

Folding and Forming

Folding and Forming

In the forming station, different mechanical arms, belts, and clamps are present that fold the blank sheets along the pre-scored lines. These devices mould and transform the blank sheets into the desired configuration carton box by folding its top, bottom and side seams.

Gluing and Sealing

Gluing and Sealing- Picture Courtesy: Fipal Srl

After forming, the glue or sealing tapes are applied at some areas of folded seams to tightly secure these folds of the formed carton. The flaps are secured shut and tightly closed using heat, pressure or other techniques.

Ejection

Carton Ejection

After successful forming and sealing, the formed carton is ejected from the machine via a conveyor belt. The ejection system present in the carton forming machine allows for the smooth removal of formed cartons from the machine.

7.What Carton Materials are Processed by the Carton Forming Machine?

A carton forming machine is a versatile piece of equipment, that processes different types of carton materials. Some of the important materials are detailed below:

Corrugated Cardboard

Corrugated Cardboard

It is one of the most frequently used carton materials. It has three layers- two flat layers and one sandwich fluted layer. It is a versatile material used for packaging diverse products. It is notorious for its excellent toughness and cushioning effect.

Cardboard

Cardboard- Picture Courtesy: Zart Art

A carton forming machine routinely processes cardboard for making trays and tuck top cartons. Cardboard is a heavy-duty paperboard material that is easily printed. It is known for its rigidity.

Paperboard

Paperboard- Picture Courtesy: Design Packaging and Tape

It is another common material handled by a carton forming machine. It is a thick paper-based material and is often used for its added strength, lightweight, and high printing qualities. It is typically utilized for making folding cartons.

Chipboard

Chipboard

Wooden-based chipboard is also processed by the carton forming machine. It is also termed as particleboard. It has less weight than paperboard. It has a smooth finish, resulting in aesthetically pleasing cartons.

Kraftboard

Kraftboard

It is a brown colour paper board that is tough. It is gaining traction for its eco-friendliness because it is easily recycled.

8.What Carton Boxes are Formed by Carton Forming Machine?

Carton forming machine forms diverse kinds of carton boxes that are listed below:

Slotted Cartons

There are two types of slotted cartons formed by the carton forming machine:

Regular Slotted Cartons Regular Slotted Cartons	It is one of the most popular styles of cartons that contain pre-scored flaps. It is a robust carton, typically employed in secondary packaging and shipping of goods.
Half-slotted Carton Half-slotted Cartons- Picture Courtesy: Atlas Container	It is similar in structure to a regular slotted carton but it features short upper flaps that join in the center. It provides easy access to cartons from the top.

Folding Cartons

Carton forming machine forms numerous styled folding carton boxes such as:

4 Corner Box 4 Corner Box- Picture Courtesy: Emenac Packaging	It contains four pre-glued flaps that fabricate the sides and bottom of the box upon folding. It has a collapsable hinge over its top.
6 Corner Box 6 Corner Box- Picture Courtesy: BlueBox Packaging	It has 6 pre-glued flaps that make an upper lid and a bottom base. It is a sturdy, protective, and durable packaging solution.
Top Tuck Carton Box Top Tuck Box- Picture Courtesy: Imperial Paper	It is a one-piece cardboard carton created from pre-folded flaps. Unlike 4 corner tox, the flaps of the top tuck carton fold at the inner side and go under the top part, thus forming a more secure seal.

Trays

Carton forming machine is also employed for forming tray boxes like:

4 Corner Tray 4 Corner Tray	These trays have 4 pre-folded flaps and are either tucked inward or outward. It offers more support when used for packaging heavier objects.
Trays with Lids Tray with Lids- Picture Courtesy: beepap.com	As the name, this kind of carton tray comes with an upper lid. It packs products for display purposes. It has pre-folded-flaps similar to 4 corner trays.
Clamshell Tray Clamshell Tray- Picture Courtesy: Deli Supplies	It has a structure similar to a clamshell with two hinges. It is formed by paperboard or cardboard and is a more secure and eco-friendly packaging unit.
Take-way Tray Take-way Tray	It has numerous pre-folded flaps that are folded to create a takeaway tray. It is often seen in take-way delivery.

9.What Options Are Available for Carton Sealing in Carton Forming Machine?

There are wide variety of carton sealing options in the carton forming machine. These sealing options result in the secure closing of carton flaps. Here is a list of important sealing options:

Cold Glue Sealing

Cartons Sealed by Cold Glue- Picture Courtesy: Gateway Packaging

Cold glue that is liquid at room temperature is applied to the flaps of the carton to create a strong bond between cartons. It does not need any heat, saving utility bills. However, it takes more time to dry and is suited to particular carton materials.

Hot Glue Sealing

Carton Sealed by Hot Melt Glue

The glue solid at room temperature is melted and then applied to the seams of the carton. This glue quickly dries, thus increasing processivity. However, it requires heat consequently, it is not budget-friendly.

Stapler Sealing

Stapled Carton

The stapler pin is used for sealing carton boxes. This type of sealing uses a stapler for closing the flaps of the carton. This sealing is popular because of its high efficiency, speed, and cost-effectivity. However, it does not create a strong bond between flaps as formed by glue.

Pressure-Lock Sealing

Pressure-lock Cartons- Picture Courtesy: Netpak

Some carton flaps have an interlocking seal that closes via pressure. It is more cost-effective, as there is no need for glue and stapler. It creates a secure sealing but is suitable for some carton boxes.

Tape Sealing

Taped Carton

Packaging tape is also used for closing the flap of a carton in some carton forming machines. It is a fast and easy way to seal the cartons.

10.What are the Add-on Features of Carton Forming Machine?

Some useful features of a carton forming machine that increase its efficiency, productivity, and consistency are:

Robotic Arm

Robotic Arm

This mechanical part can be added to the carton forming machine to eliminate the need for manual stacking of blanks in the blank magazine. This robotic arm easily lifts heavier loads and places them in the loading area.

Printers

Printed Carton Box- Picture Courtesy: Printo

Inkjet or thermal transfer printers can be integrated into the carton forming machine to label cartons with safety instructions, logos, serial number batch number, product name, business information and other related information.

Gluing Units

Carton Gluing Station- Picture Courtesy: SBL Machinery

These parts apply hot melt and cold glue for fast and effective bonding between the flaps. This unit can be easily adjusted to smear glue on different carton types.

Handles and Window Adding Stations

Carton with Handles and Window- Picture Courtesy: Superbox

This unit adds handles and other carry-on cartons for ease of carrying. Moreover, another unit adds a small clear window on the carton for viewing the inside product.

11.How To Maintain the Carton Forming Machine?

Carton Forming Machine

Maintaining is a sure way to increase the operational capacity of a carton forming machine and regular maintenance will keep the machine healthy for a long time. The maintenance schedule of carton forming machine is:

Daily Maintenance	Using a damp cloth, wipe down the exterior and interior of the machine to get rid of dust and other product buildup. Use soapy water to clear the glue applicator area. Use detergent water to open clogged glue nozzles. Check the levels of glue and refill them if required. Lubricate all rollers, screws, and other mobile parts. Check for loose nuts and screws and tighten them if needed.
Weekly Maintenance	Perform deep cleaning using cleaning agents. Check for wear and tear in seals and gaskets. Inspect the working order of sensors and recalibrate if needed.
Monthly Maintenance	Inspect wear and tear in the electric component. Tight any loose cables and wires. Check the working order of safety systems like buzzers, emergency stop buttons, alarm systems, lights, etc.
Yearly Maintenance	Conduct a thorough examination of the machine. Check for defects in any part and replace them if needed.

12.What are Technical Problems and Their Troubleshooting in the Carton Forming Machine?

Even though a carton forming machine is a sophisticated unit, it is still prone to occasional problems. These problems could cause production delays and result in loss of productive time and money. However, with some tips and tricks, these problems are easily resolved, for instance:

Cause	Solution	Picture
Jamming in Machine
Improper alignment of blanks Old or defective roller Misalignment of rollers Buildup of glue or other adhesives Poor vacuum suction force	Inspect and realign blanks in proper configuration Replace old roller Realign machine roller Clean and remove glue or other adhesives Check and reprogram vacuum settings	Jamming in Machine- Picture Courtesy: star-parker.com
Failure in Glue Application
Glue spraying nozzles are clogged. Low level of glue at the gluing station Defective pumps	Properly clean glue spraying nozzles Refill glue Repair pumps	Failure in Glue Application- Picture Courtesy: Machineseeker
Over-heating of the Machine
Ventilation filters are not cleaned properly. Old or damaged bearings High friction in the machine Electric overloading	Properly clean the ventilation filters Replace worn-out bearings Lubricate the moving parts Inspect electric overloading and shut down the machine if necessary	Over-heating of the Machine- Picture Courtesy: Hillside Custom
Improper Formation of Cartons
Poor quality glue Insufficient glue quantity Defective forming systems Old molding system Improper positioning of the sensor	Check the quality of glue and replace it. Apply an accurate amount of glue Repair and calibrate the forming section Replace old moulds Fix the positioning of the sensor	Improper Formation of Cartons- Picture Courtesy: New Products and Trends in Industry

Conclusion

A carton forming machine comes with a wide range of benefits and gives a boost to production. Accuracy, consistency, protection, and speed are a few features that make the carton forming machine popular in industries. Hopefully, by reading this guide, you have learnt about vital elements of the carton forming machine and now you can select the best carton forming machine for your businesses quite easily. Want to learn more about carton forming machine? Then click on the main Allpack website.