Why Just Open Boxes, When You Can Open The Opportunities to Save Money, Time, and Materials Too?
What is a Case Erector?
We’re sure that you want your production line to run as smoothly as possible, who doesn’t, but what happens when you can no longer keep up manually? In the beginning, forming boxes manually is manageable, but growth usually brings along higher demand for both production and supply, that’s where the need for automation starts to become apparent.
When it comes to forming boxes, ideally you’re looking for consistency in structure and production rates, both of which can easily change when you’re relying on manual labor. According to Hughes Enterprises,
“Case erectors, or case formers, are machines that take collapsed cardboard boxes and build them, then seal the bottom so they are ready to be packed… They also increase accuracy and consistency of the package.”
The two different case erectors you have to choose from are semi-automatic and automatic; if you’re a small business that’s just starting to automate, then a semi-automatic case erector will probably work best for you; however, if you have a more established business and production is consistently ramping up, then a full automatic case sealer will most likely be a better fit. According to Cisco-Eagle and Market Scale ,
- Semi-Automatic Case Erectors
- With a semi-automatic case erector, a worker is needed to open the case by hand and insert it into the machine, then the erector itself will automatically fold and seal the bottom flaps.
- Fully Automatic Case Erectors
- All an operator has to do is load flattened boxes into the loading tray, then the erector will open the carton, fold the flaps, and seal the bottom.
At this point the best course of action would be to evaluate your production line and see which case erector best suits your needs.
What are the Benefits of Having a Case Erector?
We’ve mentioned that you can save time, money and materials, but it’s a little more complex than that, so let’s break it down a bit more.
- Speed Up the Process
- Starting off with the most obvious benefit, adding a case erector onto your production line will help you speed up the box forming process. While the average person can form between 2-5 boxes per minute, our case sealers can form 10, 12 and 18 cartons per minute.
- More Structurally Sound Boxes
- Inventory tends to get damaged or lost when cases aren’t formed properly or sealed correctly; you’re guaranteed precision and security for each box. In addition, boxes that retain their 90 degree corners not only hold up better, but they’re easier to stack.
- Reducing Injuries Caused by Repetitive Motions
- According to Fitzmaurice Hand Institute, factory and assembly workers are at risk of developing carpal tunnel syndrome due to the repetitive movements of their fingers, hands, wrists, etc. to accomplish their tasks. By adding a case erector, you’re protecting your employees’ health since that repetitiveness is being taken out of the equation.
- Put Your Effort to Better Use
- According to Market Scale, forming boxes for 8-hours a day is a difficult role to fill because of the high-turnover rate, so by automating the case forming process, you’d be freeing up your time and putting personnel recourse to better use.
- Reduce the Amount of Material Waste
- By using a case erector you’re taking manual labor out of the equation, which means there’s no more room for human error. In other words, you don’t have to worry about wasting materials when boxes aren't put together correctly.
Factors to Consider Before Choosing a Case Erector
We’ve always told you all that there’s no one-size-fits-all solution when it comes to coding and marking obstacles and we’ll stand by that statement now that we’re branching into packaging. There’s actually a great article by Insite Packaging Automation that breaks down the four factors you need to consider before selecting a case erector
- What is it that you’re running through the case erector?
- Now would be the time to evaluate what it is you’re running through your case erector; what types of boxes are you working with; what are the dimensions of your case(s), what’s the quality of your case’s material? The last thing we’d want you to invest in is equipment that isn’t going to fit your needs, so before you purchase make sure to know exactly what it is you’re working with.
- What speed works best for you
- “You can make a fast case erector run slower, but you can’t make a slow case erector run faster.” While a faster case erector might be a bit pricier, it’s better to have the option to make adjustments than to be stuck at a speed that you’re bound to outgrow.
- What sealer do you prefer?
- There are pros and cons to selecting glue or tape, just like with any other factor you’ve decided on, but the choice is yours.
- If you select an erector that uses glue, then be prepared to pay 20%-30% more than an erector that uses tape; you’ll also have to provide regular maintenance since glue nozzles are susceptible to clogging; in addition, since you’re using a spray, things might get messy.
- If you’re looking for a more budget friendly erector, then the tape option might be for you, but keep in mind that a tape roll will run out faster than a glue tank. Also, tape quality will either end up costing you more money or more line stoppages.
- How long do you want your investment to last?
- If you buy an entry-level case erector you’ll more than likely outgrow it sooner than later, which means you’ll end up having to upgrade again. If you have more to invest from the beginning, then you could possibly save yourself the headache of having to upgrade packaging systems more often than you would like.
Is Your Workflow in Need of a Case Erector?
If you find that your packaging needs are starting to surpass the capabilities of your current workforce, then it might be time to start seriously considering adding a case erector onto your existing workflow. Before you decide on any case erector, make sure that you’re evaluating your current process, noting what needs the most improvement, and reaching out to an expert whenever you have any concerns.
We’ve managed to #KeepCodingSimple and now that we’re branching out, we want to #KeepPackagingSimple as well.