The Keypack Intelligent Automatic Cartoning Machine is a professional servo-driven packaging system engineered for high-efficiency automated carton loading, forming, and sealing across pharmaceutical, food, cosmetic, and consumer goods industries. This all-servo cartoning equipment delivers stable high-speed operation with intelligent fault detection, automatic alarm systems, and seamless integration capabilities with blister packaging machines, pillow packaging lines, filling systems, and labeling equipment. Designed for manufacturers requiring reliable automated cartoning solutions for blister-packed tablets, food sachets, cosmetic tubes, bottles, and irregularly shaped products in continuous production environments demanding precise carton forming, consistent product loading, and tamper-evident sealing compliance.
Product Overview
The Keypack Intelligent Automatic Cartoning Machine operates through an advanced all-servo motor drive structure controlled by PLC with HMI touchscreen interface, integrating automatic product loading, carton blank feeding, carton forming, product insertion, leaflet folding, carton closing, and sealing into a streamlined automated operation. The servo-driven architecture eliminates traditional cam-driven mechanisms and complex mechanical adjustments, enabling rapid changeover between different carton formats, precise repeatability during continuous production, and reduced maintenance requirements compared to conventional cartoning systems relying on mechanical cams and clutches.
The intelligent fault detection system automatically monitors carton blank presence, product loading status, and operational parameters throughout the cartoning cycle, preventing empty cartons from opening and minimizing material waste through real-time detection of missing cartons and product absence. When faults occur, the system immediately displays specific fault causes on the HMI screen with troubleshooting guidance, improving operational safety and reducing downtime particularly valuable for pharmaceutical cartoning requiring strict quality control and food packaging demanding consistent output without operator intervention.
The cartoning machine seamlessly integrates with upstream packaging equipment including blister packaging machines for pharmaceutical tablet cartoning matching blister output speeds, pillow packaging lines for food sachet loading into retail display cartons, filling systems for powder or liquid products requiring protective carton packaging, and downstream equipment including labeling machines for promotional stickers, coding systems for batch number printing and expiration date marking, and weighing instruments for final package weight verification in pharmaceutical quality control and food safety compliance environments.
Built with customizable automatic feeding systems tailored to specific product characteristics, the cartoning equipment accommodates solid dose pharmaceuticals including blister-packed tablets and capsules, pharmaceutical sachets containing powder medications, food sachets for instant soup or seasoning, bottles for beverages or cosmetics, tubes for hand cream or toothpaste, cosmetic containers with irregular shapes, and consumer goods requiring gentle handling, ensuring reliable product orientation and consistent loading accuracy across diverse product portfolios in multi-SKU manufacturing facilities.
Technical Specifications
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Drive System: All-servo motor drive structure (eliminates mechanical cams)
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Control System: PLC-controlled with HMI touchscreen interface
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Carton Speed: High-speed operation (specific speed dependent on carton size and product type)
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Carton Size Range: Customizable for various carton formats (tuck-end, lock-bottom, display cartons)
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Product Compatibility: Blister packs, sachets, bottles, tubes, irregular-shaped products
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Fault Detection: Automatic detection for missing cartons and product absence
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Alarm System: Intelligent fault alarm with HMI fault cause display
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Feeding System: Customized automatic product loading tailored to product characteristics
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Sealing Options: Tuck-in flaps, lock-bottom, optional hot melt glue sealing
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Integration Capability: Compatible with blister packaging, pillow packaging, filling, labeling, coding equipment
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Material Construction: Stainless steel contact parts (food-grade and pharmaceutical-grade options)
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Power Supply: Standard electrical supply (specific voltage to be confirmed)
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Operating Environment: Pharmaceutical, food, cosmetic, and consumer goods manufacturing facilities
Key Features and Machine Characteristics
All-Servo Motor Drive System for Precision and Flexibility
The complete servo motor control throughout all motion axes eliminates traditional cam-driven mechanisms and complex mechanical adjustments that require specialized technical expertise and extended changeover time. This servo-driven structure ensures precise and stable operation during continuous high-speed production while reducing setup time from hours to minutes when changing between different carton formats, improving repeatability across pharmaceutical blister pack cartoning, food sachet packaging, and cosmetic tube cartoning applications. The servo architecture minimizes maintenance requirements compared to conventional cartoning systems relying on mechanical cams that wear over time, reducing total cost of ownership and improving operational uptime in demanding pharmaceutical manufacturing and food production environments.
PLC Control with HMI Touchscreen Interface for Operational Efficiency
The advanced PLC-controlled system with intuitive human-machine interface provides real-time monitoring of cartoning speed, production quantity, operational status, and fault diagnostics accessible to operators without specialized programming knowledge. Operators can store multiple product recipes for different carton sizes and product types, adjust parameters including carton feeding speed and product loading timing, and track performance metrics including production efficiency and downtime causes for optimized production planning. This user-friendly interface simplifies operator training, reduces setup errors during product changeovers, and supports data collection for continuous improvement initiatives in pharmaceutical packaging operations, food manufacturing facilities, and cosmetic production lines requiring traceability and quality documentation.
Intelligent Fault Detection and Alarm System for Quality Assurance
The automatic detection system for missing cartons and product absence prevents empty cartons from opening and progressing through the cartoning cycle, minimizing material waste and preventing defective packages from reaching downstream equipment or final packaging. When faults occur including carton blank jams, product loading failures, or mechanical issues, the system immediately displays specific fault causes on the HMI screen with troubleshooting guidance and recommended corrective actions, improving operational safety and reducing downtime particularly valuable for pharmaceutical cartoning requiring strict quality control compliance and food packaging demanding consistent output without operator intervention. This intelligent fault management reduces scrap rates, improves first-pass yield, and supports lean manufacturing initiatives in high-volume production environments.
High Automation and Production Line Integration Capability
The cartoning machine achieves seamless synchronization with upstream and downstream packaging equipment through standardized communication protocols and mechanical interfaces, enabling complete packaging line automation from primary packaging to final case packing. Upstream integration includes blister packaging machines for pharmaceutical tablet cartoning matching blister output speeds of 60-300 blisters per minute, pillow packaging systems for sachet loading into retail display cartons, 3D overwrapping machines for promotional bundles, bottling lines for liquid product cartoning, and filling machines for powder or granule products. Downstream integration includes labeling equipment for promotional stickers and compliance labels, inkjet coding machines for batch number printing and expiration date marking, online weighing instruments for quality verification, and case packing systems for retail-ready shipper cartons, creating complete pharmaceutical packaging lines, food production facilities, and cosmetic manufacturing operations with minimal manual intervention.
Customizable Automatic Feeding Systems for Diverse Products
The customized automatic product loading and feeding systems are specifically engineered and tailored to accommodate unique product characteristics including size, shape, weight, fragility, and orientation requirements across diverse applications. The feeding systems handle solid dose pharmaceuticals including blister-packed tablets and capsules requiring gentle handling to prevent blister damage, pharmaceutical sachets containing powder medications needing precise orientation for leaflet insertion, food sachets for instant soup or seasoning requiring high-speed loading from pillow packaging machines, bottles for beverages or cosmetics with varying heights and diameters, tubes for hand cream or toothpaste requiring specific orientation for brand visibility, cosmetic containers with irregular shapes demanding custom fixtures, and consumer goods requiring gentle handling to prevent scratches or damage, ensuring reliable product orientation and consistent loading accuracy across multi-SKU manufacturing facilities with frequent product changes.
Optional Hot Melt Glue Sealing System for Tamper-Evident Closure
The optional hot melt adhesive spray sealing system provides secure carton closure as an alternative to traditional tuck-in flaps or lock-bottom carton styles, applying precise adhesive patterns to carton flaps for tamper-evident sealing and enhanced carton integrity during distribution and retail display. This sealing option is particularly suitable for pharmaceutical cartoning requiring tamper-evident sealing for regulatory compliance with FDA and EU pharmaceutical packaging directives, food packaging demanding enhanced carton integrity during distribution to prevent product exposure and contamination, and premium cosmetic packaging requiring secure closure for retail presentation and brand protection. The hot melt system operates at controlled temperatures with adjustable adhesive application patterns, ensuring consistent seal quality without damaging heat-sensitive products or carton graphics.
Servo-Driven Changeover for Multi-SKU Flexibility
The servo motor architecture enables rapid format changeover between different carton sizes and product types through electronic parameter adjustment rather than mechanical part replacement, reducing changeover time from 2-4 hours typical of cam-driven cartoning machines to 15-30 minutes for servo-driven systems. Operators store carton format recipes in the PLC memory including carton dimensions, product loading positions, and sealing parameters, then recall saved recipes through the HMI touchscreen for instant parameter loading without manual measurements or mechanical adjustments. This quick-changeover capability is particularly valuable for contract packaging operations serving multiple clients, pharmaceutical manufacturers producing various tablet strengths requiring different carton sizes, food producers with seasonal product variations, and cosmetic brands with frequent promotional packaging changes, maximizing equipment utilization and reducing setup waste in multi-SKU production environments.
Application Areas
Pharmaceutical Industry: Blister Pack Cartoning and Medication Packaging
Pharmaceutical manufacturers utilize this automatic cartoning machine for blister-packed tablet and capsule cartoning with automatic leaflet insertion for prescription medications including antibiotics, cardiovascular drugs, and pain relievers, vial packaging for injectable medications with protective foam inserts preventing glass breakage, pre-filled syringe cartoning with needle safety caps for diabetes medications and vaccines, medical device packaging for diagnostic test kits and blood glucose monitors, pharmaceutical sachet cartoning for powder medications including oral rehydration salts and antibiotic suspensions. The servo cartoning system ensures precise carton loading matching blister packaging output speeds of 60-300 blisters per minute, gentle handling to prevent damage to fragile blister packs and glass vials, and compliance with pharmaceutical packaging standards including serialization codes for track-and-trace requirements, tamper-evident sealing for regulatory compliance with FDA 21 CFR Part 211 and EU Falsified Medicines Directive, and integration with vision inspection systems for carton quality verification in pharmaceutical manufacturing facilities serving retail pharmacy, hospital supply, and international export markets.
Food Industry: Sachet Cartoning and Food Product Packaging
Food manufacturers deploy this cartoning equipment for high-speed food sachet cartoning including instant soup powder sachets loaded from pillow packaging machines into retail display cartons, seasoning blend packets for taco seasoning and pasta sauce mixes, condiment packets including ketchup, mustard, and mayonnaise sachets in foodservice bulk cartons, instant beverage powder sachets for coffee, tea, and hot chocolate with promotional outer cartons, chocolate bar cartoning with inner protective trays preventing product damage, biscuit packaging with product orientation for standing display on retail shelves, confectionery products including candy boxes with window cartons for product visibility, frozen food cartons for ready meals and pizza packaging, snack food packaging for granola bars and protein bars. The cartoning machine accommodates food manufacturers requiring hygienic cartoning solutions with stainless steel contact parts meeting FDA food-contact requirements, quick changeover for multiple SKUs in co-packing facilities, and integration with metal detectors or checkweighers for quality control and regulatory compliance in food production facilities serving retail grocery, foodservice distribution, and vending machine supply channels.
Cosmetic and Personal Care Industry: Beauty Product Cartoning
Cosmetic manufacturers employ this servo cartoning system for automated cosmetic tube cartoning including hand cream, facial cleanser, and sunscreen tubes with product information leaflets and promotional inserts, lipstick packaging in premium cartons with protective foam inserts preventing cosmetic damage, skincare product bottle cartoning for serums, lotions, and toners with instruction leaflets and sample sachets, perfume box packaging with custom foam inserts for bottle protection during shipping, soap bar cartoning in individual retail display cartons, toothpaste tube packaging with promotional outer cartons for retail presentation, personal care item cartoning including razors, cosmetic applicators, and beauty tools. The servo-driven cartoning equipment ensures gentle handling of premium cosmetic packaging to prevent scratches and maintain brand image while maintaining high-speed operation for mass production of beauty and personal care products, supporting cosmetic manufacturers serving retail beauty stores, department store cosmetic counters, and e-commerce direct-to-consumer channels with premium packaging requirements.
Consumer Goods and Daily Necessities: General Product Cartoning
Consumer goods manufacturers utilize this versatile cartoning machine for toy packaging in retail-ready cartons with window displays for product visibility, stationery product cartoning including pen sets, marker packages, and office supplies with hanging tabs for retail display, hardware item packaging for screws, fasteners, and small tools in display boxes with product specifications, auto parts cartoning for oil filters, spark plugs, and automotive accessories with installation instructions, household goods packaging including light bulbs, batteries, and small appliances in protective cartons, general consumer products requiring retail presentation and brand visibility. The cartoning system accommodates diverse product shapes from flat items to bulky components and various carton formats from tuck-end boxes to display cartons with windows, supporting manufacturers with varied product portfolios serving retail stores, hardware distributors, automotive aftermarket channels, and e-commerce fulfillment operations requiring efficient cartoning automation.
Production Line Integration: Complete Packaging Automation
The cartoning machine integrates seamlessly into complete packaging lines with upstream pillow bag packaging machines for sachets before cartoning operations, 3D overwrapping machines for promotional bundle packs combining multiple cartons, blister sealing equipment for pharmaceutical tablet packaging before carton loading, sachet filling machines for powder or liquid products feeding into cartoning line, and downstream labeling machines for promotional stickers or compliance labels including nutrition facts and ingredient declarations, coding systems for batch number printing and expiration date marking using inkjet or thermal transfer technology, weighing instruments for final package weight verification ensuring regulatory compliance in pharmaceutical quality control and food safety requirements, and case packing systems for retail-ready shipper cartons in pharmaceutical packaging lines, food production facilities, and cosmetic manufacturing operations requiring complete automation from primary packaging to palletized finished goods.
