Accumulation, check systems, case packing, sleeve wrapping, palletising and distribution planning.
Use accumulation deliberately
Buffer between machines so a short stop does not halt the whole line. Size accumulation for the expected fault and recovery time, not as an unlimited store.
Inspect before secondary packing
Position checkweighing, metal detection, vision, barcode checks and leak testing where failed packs can be rejected safely and traced.
Choose secondary packaging
Cases, trays, shrink bundles and sleeves have different material, labour and transport performance. Test the complete shipper with the product orientation and weight.
Automate case handling
Case erectors, tapers, sealers and robotic packers can reduce repetitive work. Confirm case quality, flap control, tape or adhesive and changeover requirements.
Palletise and stabilise
Define pallet pattern, height, weight, slip sheets, stretch wrap and label application. Include forklift access and warehouse constraints.
Design safe access
Conveyors and robots need guarding, interlocks, safe intervention and maintainable access without creating trapping or ergonomic hazards.
Common questions
How much accumulation does a line need?
Enough to absorb realistic short stops and allow controlled restart. Calculate from line rate, fault frequency and recovery time.
Should inspection be before or after labelling?
Place each check after the feature it verifies. Weight may be checked after filling; barcode and label identity after labelling; case label after case sealing.
When does robotic case packing make sense?
When speed, pack weight, repetitive labour, presentation or multiple pack patterns justify it and the upstream line can provide products consistently.