High Speed Cartoning Machine: The Complete Buying Guide In 2025

1.What is high speed cartoning machine?

AIPAK automatic high speed cartoning machine

A high speed cartoning machine is specialized packaging equipment that is completely automated, specifically used for inserting the final product rapidly into the cartons and efficient packaging. These high speed machines are 2-3 times more efficient than the traditional cartoning system.

These machines are able to pack hundreds of cartons per minute, which makes them time efficient and ideal for especially large scale industries, where a large volume of packaging is required without any compromise of the quality and consistency.

2.Which industries require the use of high speed cartoning machines?

Different types of products packed in cartons

The main high scale industries included are as follows:

Pharmaceuticals:

Pharmaceutical products packaging – Picture courtesy: Oliver Inc.

The pharmaceutical industry use the high speed cartoning machines to pack tablets, blister packs, liquid dosage forms including syrup bottle, ampoules, vials and many other products including powder dosage forms, and all this packaging is done in regulated and controlled environments. Packaging of hundreds of batches being produced daily is fastened and done efficiently through the automatic high speed cartoning machines.

Food:

Different type of food packed – Picture courtesy: pixart printing

The food industry is revolving so much and there is a lot of variety in the food industry now a day, so these packaging machines also hold a very important place in the food and beverages industry. The processed food which has a high demand in today’s world requires a very good quality with packaging with special parameters. Other products include tea bags, cereals, confectionery and even fruits and vegetables are also packed.

Beverages:

A pack of beverages – Picture courtesy: vecteezy

The beverages are usually packed in glass containers which require secure and effective packaging technique to minimize the loss and handling is made easy through the high speed cartoning machines.

Cosmetics:

carton of cosmetic products – Picture courtesy: ruby print and pack

With so much competition in the market for every product, the packaging plays a very crucial role about the marketing of a product. These cosmetics products, either they are skin care, hair care or fragrances, a good or cost effective packaging requires the right equipment.

Household Products:

Different household items packed – picture courtesy: Carton service

All the household items you see every day around you requires a proper carton packaging, including cereals, eggs, tea, cleaners etc. Even the fruits and vegetables we buy on daily basis come in properly packed carton. The tetra packed milk is a very common example of the carton packaging, protecting milk from going bad.

Fresh fruits packed in cartons – picture courtesy: stora enso

Electronics:

Carton packaging for electronic devices –Picture courtesy: packoi

The electronic devices need to be packed properly with proper protection to avoid any damage to the equipment body; therefore the electronic device industries are using high speed cartoning machines for effective packaging.

Tobacco Industry:

Tobacco packed in different forms and packages – picture courtesy: sewtec

The speed and uniformity of the package is very crucial in the tobacco industry as well, the high demand and large number of batches being prepared per day require high speed cartoning machines to meet the needs.

So basically, any industry which has a high volume and a standard packaging requirement, high speed cartoning machine is an integral part of their production.

3.What are the main types of high speed cartoning machines?

The high speed cartoning machines are available in different configurations, depending upon their mode of automation and loading mechanism, mainly the types include:

Depending upon the loading mechanism , they are:

Horizontal Cartoning Machines:

AIPAK horizontal cartoning machine

Horizontal cartoning machine load the product from side of the carton. It is suitable for solid, regular shaped products. They are mainly used for blister packs, tubes, bottles and sachets. They are also suitable for items that are long or irregular in shape and need to be placed from the side of the carton.

The key advantage of horizontal cartoning machine is that it is very versatile due to its ability to handle a wide range of size and shape. Also, horizontal cartoning machine has small foot print which makes it more suitable for small spaces.

Vertical Cartoning Machines:

Vertical cartoning machine – picture courtesy: endflex

Vertical cartoning machine load products vertically, load products from the bottom of the machine and insert the product into the carton from the top of it. Vertical cartoning is suitable for products that are difficult to stack and need to be filled from bottom.

The products packed here are better suited for vertical placement, such as sachet, pouches or bulk powders. The vertical cartoning machines are suitable for complex products which have multiple components, like kits or multipacks.

Depending upon the degree of automation:

Semi-automatic cartoning machines:

Semi-automatic cartoning machine – Picture courtesy: Parth EC

The semi-automatic cartoning machine is a compact intermittent vertical cartoning machine. The cartons are placed manually in the carton loading channel, the machine uses a vacuum cup to suck the cartons and feed them into the rotating wheel, also referred to as star wheel due to its working pattern.

The product is added manually in the opened cartons rotating along the belt, after that the cartons are rotated for the flap folding mechanism. After this whole procedure is completed the packed cartons are pushed out automatically from the other side of the rotating wheel and collected manually.

Fully automatic high speed cartoning machines:

These automatic cartoning machines have continuous horizontal system running smoothly. Automatic cartoning machines smooth pulls and erect a carton from the carton stack and insert the product precisely, securing them and sealing the carton with either tuck or glue options as per the instructions and requirement.

High speed automatic cartoning machines have interlock features, means “no carton, no product”, which guarantees the accuracy and efficiency. These characteristics make it the best choice for high end products, along with folding cartons.

4.What is the Principle of High Speed Cartoning Machines?

A visual presentation of working mechanism of automatic cartoning machine- Picture courtesy: SiroSilo

High speed cartoning machines work on the principle of automation combined with mechanical and pneumatic systems. A simplified version of how they work is given below:

Feeding and forming of carton:

Flat carton stack fed into the automatic cartoning machine-Picture courtesy: Bhagwati pharma

The machine pulls the flat, precut cartons from the carton stack and converts it by folding it into final shape by series of events taking place automatically.

Positioning of cartons:

Cartons opened up and positioned to add the product in – Picture courtesy: R.A Jones

The machine use suction cups usually to pull and position the formed carton. The carton is then moved to the filling station where products are filled.

Product Loading:

Product bottles being added into open cartons – picture courtesy: marchesini group

The product is inserted into the opened cartons, either top, bottom, horizontally or vertically, depending upon the type of machine used.

Carton Closing:

Cartons being tucked in for closure after inserting products –Picture courtesy: siro silo 

Once the carton is filled with the product, the cartons are sealed using flap folding mechanism or may be by using glue or tuck in closures as per the requirement.

Ejection:

The sealed cartons are then ejected onto a conveyor belt for further required processing, which may include printing or labeling and addition of leaflets in the cartons.

Addition of leaflet along with the product in the carton

There are sensors and programmable logic controllers (PLCs) which ensure accurate programming of all stages, including automatic inspection and ejection of the defective cartons, handling variances in product size or speed.

5.What are the parts of high speed cartoning machine?

The high speed automatic cartoning machine usually comprises of a control panel, electrical components, lubrication system, printing system, conveyor systems, safety sensors and a carton loading and packaging system. The key parts are described under:

Conveyor and drive system:

Conveyor belt system-Picture courtesy: integrated packaging machinery

Conveyor system plays an important role in arrangement and transportation of the product and carton to the cartoning area. This system makes sure that the products are delivered to the cartoning machine in a systematic and controlled manner.

It makes sure the smooth product flow and precise timing during the packaging process.

Carton storage:

Precut flat cartons storage – Picture courtesy: best suppliers

It holds the precut flat cartons for feeding into the system.

Carton forming unit:

Cartons given proper shape before inserting products.-Picture courtesy:  process technology

The carton forming unit is responsible for converting flat cardboard being fed from the magazine into fully formed boxes. It implies the mechanism of suction cups and folding arms for this procedure

In this process, the quality of the carton molding is directly affected by the accuracy of the suction cups. And the automatic cartoning machine can be applied to different sizes and designs of cartons.

Product loading device:

Addition of the product in blank cartons – Picture courtesy: Siro Silo

The product loading device consists of a robotic arm that carefully places the product into the formed carton. This can be horizontal or vertical depending upon the machine. This assembly efficiently processes a wide range of product types and sizes, while maintaining the precision and speed. It is customized according to different product configurations for damage control.

Carton sealing device:

A temper evident sealed carton– Picture courtesy: graphic packaging

The packaging of the carton is completed by the carton sealing device. The carton is sealed by lock flaps, glue or tape depending upon the type of product and machinery.

Control panel:

Control panel of the high speed cartoning machine-Picture courtesy: shpex pack

This is the quality check system and the whole working of cartoning machine is dependent upon the control panel. All the commands are feed here. It includes a PLC (Programmable Logic Controller) for automated control and a touchscreen for displaying information and making the required adjustments.

It also detects problems like incomplete sealing, damage packaging and it also remove the defective item from the line.

Printing system:

Some of the automatic cartoning machines also provide labeling and printing of the cartons so they are provided with inject printers to print the labels, dates and other required information on the cartons.

6.What Are the Main Advantages of High Speed Cartoning Machines?

Different types of cartons used in daily life –Picture courtesy: RK Packs

High speed cartoning machines have made the industrial packaging faster and more efficient. The high speed cartoning machines have inbuilt very precise software and mechanism that enables them to effectively draw, open, wrap and close a carton.

On a bigger scale, these machines are often further attached in larger production lines to simultaneously carry out the other final operations such as product filling, sealing and labeling. The main and very common benefits include:

Increased Efficiency:

Capable of handling hundreds of cartons per minute.

Consistency:

Maintains uniform quality and appearance and size of packaging.

Reduced Labor Costs:

Automation of the machinery minimizes the need for manual assistance and reduces the labor cost.

Scalability:

Due to fast and efficient working output, high speed automatic cartoning machines are ideal for companies looking to scale up their production.

Improved Product Safety:

The advance control systems make sure the secure sealing and tamper evidence for the safety of consumer as well as maintain the brand integrity.

Enhanced Integration:

The seamless connection and coordination of the high speed cartoning machine within itself and along with other machines in the production line enhance the overall efficiency and accuracy.

Compliance:

The high speed cartoning machine meets industry-specific packaging requirements, especially for the pharmaceutical industry.

These advantages make high speed cartoning machine a smart investment for large-scale manufacturing.

7.Is high speed cartoning machine customizable for specific production needs?

Cartoning of the cans in high speed cartoning machine – picture courtesy: BW integrated system

The high speed cartoning machines are very versatile advanced. So, yes they are highly customizable. They can modify the structure and features of the carton as required by manufacturer. Customization may include:

Size and shape variation:

High speed cartoning machine can pack cartons of different size and style.

Fragile products:

These machines comprises of special feeders for fragile or irregular-shaped products.

Multiple language:

The control panel allows you multiple language user interfaces, so manufacturer can choose the language of their choice.

Sterilization an tracking modules:

There are serialization and tracking modules in high speed cartoning machine which are very important, especially in the pharmaceuticals, medical devices, and food industry, where traceability, anti-counterfeiting and regulatory compliance are very critical.

Material handling integration:

The high speed cartoning machines have material handling integrations like robotic arms, automatic guided vehicles (AGVs) for the transportation, loading, unloading and handling of materials without human input.

Clean room compatible models:

In the pharmaceutical industry, all the equipment and machinery should be clean room compatible; hence the high speed crtoning machines have clean room compatible models for pharmaceutical use.

Data collection and reporting capabilities:

The high speed cartoning machines have sensors, controllers and vision system that are continuously collecting the data of production count, machine status, rejected cartons, quality metrics and even temperature and pressure data which plays and important role in optimized performance traceability.

8.What carton styles and closures are supported in high speed cartoning machines?

Different forms of carton packing – picture courtesy: uom enterprise

Due to the versatile nature and advance mechanism, high speed cartoning machines are compatible with various cartons styles, including:

Straight Tuck End (STE)	Picture courtesy:custom boxes hub
Reverse Tuck End (RTE)	Picture courtesy: fantasta pack
Seal End	Picture courtesy: emenac
Hinged Lid or Flip-Top
Sleeve Cartons	Picture courtesy: oxo packaging
Tray and Cover	Picture courtesy:rajapack

Depending upon the method of closing the carton, the high speed cartoning machine can support:

Glue sealing:

Some cartons require sealing from both side of the carton, the sealing can be done through hot or cold melted adhesives to create air tight and water tight seals on the cartons. The machine uses heat and pressure to melt the adhesive on the carton’s flap and creating a sealed closure.

Tuck-in flaps:

This is the most common form of carton closure. It is usually for the reclosable packaging cartons. The top and bottom of the carton can be closed and kept stable just by two dust flaps and one tuck in flap.

Locking tabs:

Locking tabs in carton packaging is done to lock and seal the carton without using any glue or adhesives. This is a self-locking mechanism; it is easy to and secure. It is more common in pharmaceutical and cosmetic packaging.

Tamper-evident seals:

The tamper evident packaging of the cartons is done in a way that if once opened, it’s not possible to reclose the carton without leaving visible sign of tampering or opening of the carton. It helps to enhances product security, especially in pharmaceutical industry, in food industry.

The type of carton packaging and closure totally depends on the product’s nature, the manufacturer and the consumer convenience.

9.What is the maintenance schedule for optimal performance in high speed cartoning machines?

A close-up photo showing the details of high speed cartoning machine-Picture courtesy: ACMA

The regular maintenance of the machinery is the key to ensure an optimal performance and longevity of the equipment. A typical maintenance schedule usually includes:

Cleaning and lubrication:

The regular cleaning and lubrication of the conveyor belt is essential to prevent any wears and smooth surface ensure smooth movement of the cartons. The lubrication of all other parts like gears and bearings is done according to the requirements.

Inspection:

During inspection, the electrical wiring and connections are checked for any damage, loose connections or power loss. Inspection for any kind of wears and damages is required to be done regularly.

Preventive maintenance:

It is always advisable to schedule regular inspection for maintenances including cleaning, lubricating and other trouble shooting of the machinery. Usually, troubleshooting includes checking for jams, miss alignments, and malfunctions.

The regular testing of PLC and timely replacement of worn out parts is recommended.

Addressing downtime:

Downtime is the result of negligence in keeping the update of the equipment and unexpected failures, which can be easily avoided by doing regular preventive maintenance and deep inspection of drive systems and motors.

The regular and optimum maintenance can avoid a lot of mechanical failures, preventing any damage and downtime to the machine.

10.What are the factors to consider before purchasing a high speed cartoning machine?

Internal assembly details of the automatic cartoning machine –picture courtesy: SRT

When purchasing a high speed cartoning machine, here are a few tips to keep in mind to help you through the whole procedure:

Production capacity and speed:

The initial step is to determine your production needs, by calculating your daily, weekly or monthly production rate to determine the required output of the machine. Keep in mind the possible production increase, termed as “surge capability” so that you can get the real value.

Ensure that your machine speed aligns with production rate and your other specific requirements.

Product and carton compatibility:

The product will decide the type of cartoning machine used; either it will be vertical or horizontal. So start by identifying the products to be packed, e.g. tubes, bottles, blister packs and their dimensions.

Determine the type and size of cartons to be used, including the type of sealing method to be used, than ensure that the specific machine can handle your specific type of carton.

Machine features and capabilities:

The level of automation of the machine should be considered and how well it aligns with the current production line. Choose the appropriate sealing method for the cartons could be the use of adhesives and or fold in lid cartons. These are included in the machine features.

The machines that offer a remote access to monitor the whole procedure, maintenance and upgrade capabilities are the best choice.

Budget and long term cost:

Apart from the cost of the machine itself, the cost of installation, maintenance and training of operating personnel should also be included while calculating the budget for the machine. Also, consider the environmental impact of the machine, the energy consumption by the machine and the cost of spare part and support service.

Practical considerations:

The installation space, technical support, parts availability and service compatibility are some other factors to consider while purchasing a high speed cartoning machine, not to forget the delivery time it will take to be delivered, especially if you have a tight dead line.

Conclusion:

High speed cartoning machines are very important and impactful tool in the manufacturing industry in today’s world. They are streamlining and speeding up the packaging process with so much efficiency and reliability. It doesn’t matter if you are in a pharmaceutical or a food industry, electrical or house hold items industry, cartoning machine is need of the hour in every industry and investing in the right cartoning machine will boost your production quality. The right understanding of how these machines and the consideration before buying the machine you are building a better and efficient future of your business. For more information feel free to contact our AIPAK team now.