What Is the Best Case Packing Solution for High-Speed Bottle Packaging Lines?

When it comes to selecting a case packing machine for a bottle packaging line, it's not all about speed. The machine must also reliably manage bottles, comply with the necessary carton format and minimise changeovers and material losses. A system that works well with one bottle size may not work with a line that has a number of products.

If production is relatively high with a steady bottle size and case configuration, a wraparound case packer might be a good choice. It wraps a corrugated case around a cluster of bottles, and can also save board usage compared with other conventional case configurations. If the line is meant to produce more than one bottle size, or more product configurations, a robotic top-loading case packer might be a better option. For particular bottle and case designs, side load systems can also be appropriate.

The right selection depends on the bottle design, desired output, case requirements, production run and available floor space. In this guide, we’ll be examining the key case packing options available and the factors that manufacturers should consider before purchasing a bottle case packing machine.

The Three Main Types of Bottle Case Packing Solutions

Although bottle case packing systems come in different designs, three common options are wraparound, top-load, and side-load case packers. They differ in how products enter the case and how the packaging process is organized.

Why Consider a Wraparound Case Packer for High-Speed Bottle Lines?

For manufacturers that need to make large numbers of bottles with relatively consistent bottle pack formats, a wraparound case packer may provide a number of running advantages. Whether or not those benefits translate into better overall performance hinges on the application.

High throughput packaging can be achieved with wraparound systems. They manage the grouping, blank feeding, case forming and sealing in a single process.

However, a machine's rated speed is only part of the picture. Also, the actual production rate depends upon bottle spacing, bottles per case, upstream accumulation, carton quality and downstream equipment.

A case packer that is capable of packing a certain number of cases per minute may not be able to pack that many cases consistently if the bottles are not coming into the packer evenly or the case sealer is a bottleneck. Evaluate the expected sustained line speed rather than relying on the headline machine rating alone.

Since a wraparound case wraps directly over the grouped product, it can require less corrugated board than some regular slotted container (RSC) designed box cases.

The amount of material saved varies depending on the size of the case, board grade, overlap and sealing needs, product configuration, and compression needs. A smaller carton isn't necessarily a better carton if it reduces the protection in storage or transit.

Compare the dimensions of actual blanks and board specifications of the proposed packaging formats before deciding to purchase. A packaging trial can be used to determine if the material savings are significant.

A proper wrap-around case can minimize the movement of bottles when transported. This is especially crucial if a case includes glass bottles or products that will be damaged by impact.

However, the external carton cannot alone be used to measure the protection of bottles. These are all factors that contribute to the damage risk: bottle spacing, dividers, case strength, palletizing pattern and distribution conditions.

When there is a fragile product, consider the whole packaging system (not just the tighter case) and make sure the product doesn't break.

When Does a Traditional Case Packer Make More Sense?

Not all production lines benefit from wraparound packaging. For certain uses, flexibility and product handling needs are more important than maximizing output for a single product format.

Changeover needs are critical for a plant that uses multiple bottle sizes, shapes or case patterns in each shift.

A Robotic Top Load Case Packer can help to streamline some of the changes using programmable movements and product recipes. But a different bottle or case type might need different grippers, mechanical adjustments and/or settings.

With the correct format modifications, wraparound machines and side-load machines can also aid in efficient changeovers. The key is to look at the real-life changeover process for the actual machines being considered.

Ask each supplier to demonstrate a changeover between your intended formats. Record the time required for adjustments, tool changes, recipe selection and production verification.

Square, oval, tall, narrow and oddly shaped bottles will act differently in conveying and case loading. Some can be grouped and moved easily; others will need special guides, special grippers, or carefully controlled movement.

Wraparound systems typically require bottles to arrive in an orderly sequence. The robotic top-load system may offer greater freedom of product placement; however, the robot and gripping tool must be able to grip the bottle securely.

Send bottle samples and drawing to suppliers prior to finalizing a machine specification. Testing the actual product is more reliable than selecting equipment from a more general description of the bottle.

Some retailers and distribution systems have certain specifications for carton size, carton structure, or position of carton labelling. These requirements can restrict the available packaging options.

If the plant must rely on pre-formed cases, a top load or side load case packer might be more feasible than a wraparound system. If the carton design can be changed, it may be worth comparing both options before making the final decision.

Quick Comparison: Bottle Case Packing Solutions

The table below provides a summary of the key differences. It is designed to be used as a selection guide only and not a guaranteed performance ranking.

Actual speed, material consumption, changeover time and footprint is dependent on the respective machine and application. Request suppliers to verify performance with your bottle samples, case specifications and your desired operating conditions.

What Factors Should You Evaluate Before Buying a Bottle Case Packer?

The best case packing solution is not necessarily the machine that has the highest rated packing speed, but the one that fits the whole production process.

Start by discussing the height, diameter, shape, weight and contents of the bottle. Lightweight plastic bottles may be more susceptible to tipping or moving during conveying and glass bottles may require additional impact protection.

Look for any other characteristics of the bottle, including unusual shoulders, narrow necks, protruding caps or labels that may be touching adjacent products or package materials.

Calculate the real number of cases the line must make in a minute/hour. Include number of bottles per case and any production growth that is anticipated.

Case packer may not be able to catch up with the filler. Other influences which reduce overall throughput are upstream conveyors, bottle accumulation, case sealing and downstream palletizing.

Request the operating rate that can be expected under your operating conditions (bottle layout, case size and production schedule)

The needs of a line that is making one bottle size for a long production run are different from that of a line changing several SKUs daily.

List bottle and carton formats the machine needs to process. Then, discuss with your supplier what changes can be made with software and what changes would require mechanical changes or new tooling.

The machine that is successful with one SKU can become less productive if the changeover is time-consuming with a lot of manual tasks.

Machine performance is affected by case dimensional size, board grade, blank consistency, folding requirements and sealing requirements.

If blanks are not cut well or are cut inconsistently, it can result in feeding errors, folding problems, jams or unreliable sealing. These problems are particularly relevant with high-speed lines.

Test the suggested machine with the corrugated blanks to be used for the production before confirming the order. When multiple suppliers are being considered, use similar carton specifications, if possible.

Remember that it's not just about the size of the case packer. The complete installation may require space for bottle infeed, accumulation, carton blank storage, operator access, maintenance, case conveying and downstream equipment.

A wraparound system might need space for the blank magazine and case forming area. A robotic top load cell may require robot motion clearance, guarding and maintenance access.

Before buying, check the proposed line layout for installation challenges or restrictions on access after commissioning.

The initial cost of the machines is not the complete cost of operating a case packing line. A meaningful comparison should include:

If material savings in the plant can be verified at the actual volume of production, a wraparound case packer can be worth the initial investment. Alternatively, a flexible system may be more beneficial if the product line is changing often.

Estimate the payback period, using actual operating data. Do not use production thresholds or estimated savings from others that have not been certified for your use.

Common Mistakes When Selecting a Bottle Case Packing Machine

High rated speed is no assurance of high daily output. The number of cases produced during a shift may be lowered if there are frequent jams, if the bottle flow is uneven, if changeovers are difficult, or if there are restrictions downstream.

Discuss the anticipated sustained throughput, and how the supplier verifies performance in realistic production settings.

The case packer can only work reliably if the bottles arrive in the correct number, spacing and orientation.

Bottle flow instabilities can lead to grouping errors, tipping and multiple machine stoppages. A consistent supply to the packing station can be achieved by appropriate conveying, accumulation and spacing equipment.

A good case packing machine can't work wonders with poor blank quality. Some dimensional, cutting quality, board stiffness or moisture differences may influence feeding/case formation.

Before buying it, test the proposed carton material and verify the allowable blank specifications with the equipment supplier.

There is potential for a future expansion of the bottle range after initial installation. Requirements for gripping, grouping and case forming may vary with new sizes, packaging designs or production targets.

When evaluating equipment, ask which future formats the proposed configuration can support and what additional tooling or modifications may be needed.

What Should You Test Before Buying a Bottle Case Packer?

A supplier demonstration should use your actual bottle and packaging materials whenever possible. A standard demonstration product may not reflect the handling challenges of your production line.

Before approving the machine, consider checking the following:

Agree on the test conditions and acceptance criteria before the trial. These should reflect the actual product, carton specification, operating rate, and quality requirements.

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