Case & Tray Forming 101

The corrugated industry offers many options to businesses to help them meet their packaging and shipping needs. Customers can choose from a variety of corrugated material and box styles to meet the demands of their products and the industry in which they operate. However, this is only the beginning.

The world of packaging goes beyond corrugated to include, among other aspects, the process of case and tray forming. The purpose of this paper is to explore the options available to customers and explain how these different options work.

The Challenge
In addition to the properties of corrugated material and the features of different cases, customers need to be aware of the factors that can adversely affect the quality and behaviour of corrugated during the forming process. For example, in dry weather corrugated can get hard and coarse and in wet weather it can become soft.

Other factors adversely affecting the quality and behaviour of corrugated include:

  • The type of scoring applied by the manufacturer
  • The type of corrugated material used
  • The age of the corrugated material
  • The design of the box
  • Responding to Customer Needs

The number one problem encountered by customers is overcoming the variables in corrugated quality that can disrupt the corrugated forming process. The first step to overcoming these variables is to understand them. The second step is to find a solution that has been designed to meet the needs of corrugated, rather than one that makes corrugated conform to its features. Whether customers form corrugated boxes manually or automatically, the simplest solution is often the best solution.

Technology & Mechanics
To help ensure reliability in case forming, the erecting process is separated into simple steps. Each step is well defined and simple. The process is seamless, and appears to be continuous, but they are in fact a series of steps that work together.

Servo Driven Mechanics
Sensors at each step in the case forming process ensure that each step is completed successfully before moving to the next step. Since not every step takes the same amount of time to complete, the start of some steps can be delayed until the previous one is completed. This timing can be adjusted to compensate for different types of cases and trays.

Principles of First Case Separation
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