Cartoning machine common problems and solutions

Whether you are a manufacturer in the pharmaceutical, food or cosmetic industry, cartoning machine equipment is an essential part of your production line. As an important part of the production line, cartoning machines have a direct impact on the efficiency and quality of product packaging. However, it's inevitable that you'll encounter problems during use that can lead to downtime or a drop in packaging quality. Understanding these common problems and their solutions can help avoid production downtime and improve overall productivity. Next, we will discuss in detail several major problems that can occur during the use of cartoning machines and the corresponding response methods.

Carton material jamming problem

Box jamming can be one of the biggest headaches when cartoning machines are operating at high speeds. Boxes get stuck on the conveyor belt or during folding, causing the entire production line to pause. Most of the reasons for this problem are related to the material or size of the box, or a malfunctioning mechanical part. For example, using a box material that is too hard or too thin increases the risk of a jammed box, and a conveyor belt that has foreign objects or worn mechanical parts may also prevent the box from passing through smoothly.

Solution  

It is very important to choose the right material for the box, especially if the material thickness is moderate according to the working parameters of the cartoning machine. If the machine itself has wear and tear problems, it requires regular maintenance, especially cleaning and lubrication of the conveyor belts. It is also important to ensure that the machine molds are correctly sized so that the boxes do not jam during folding and transfer. Tests should be carried out in advance before each production run to confirm that all links are in optimum condition.

Problems with poor or leaking adhesive

Poor box encapsulation is another big problem that affects product quality. This problem is often caused by unstable working temperature of the gluing machine, poor quality of glue or clogging of the equipment's glue spraying system. If the box is not firmly glued at the sealing place, the packaging effect of the product will be greatly reduced, and even affect the final sales.

Solution  

First of all, make sure the temperature of the gluing machine is running in the right range, avoid the temperature is too low to cause the glue can't be completely melted, or too high to make the glue liquidity is too strong. Secondly, choose a quality glue, especially one that is compatible with the box material used, so as to ensure the pasting effect. Regular cleaning of the nozzle to prevent clogging is also essential, especially after a long period of continuous production, the nozzle is very easy to produce glue residue, affecting the uniformity of spray glue.

Product feeding is not smooth

In the cartoning process, whether the product can enter the box smoothly is a key step. Poor feeding is usually manifested in products stuck on the conveyor belt or unable to be accurately placed into the box. This problem can be caused by a malfunction in the feeding system, product size mismatch, or sensor malfunction.

Solution  

In this case, the feeder system needs to be inspected in detail to ensure that the conveyor belt is free of obstructions and that the chute is operating smoothly. In addition, the feeder needs to be adjusted to the size of the product, especially if the product has a special shape, and the design of the feeder must be precisely matched. If the problem is with the sensors, they need to be tested and calibrated in a timely manner to ensure that they are sensing the product in the correct position.

Inaccurate folding or damaged boxes

The folding function of the cartoning machine determines the final appearance quality of the package. Inaccurate folding or damage to the box during folding not only affects the aesthetics, but may also prevent the package from being completed successfully. This problem is often related to the wrong position of the guide rails, and material that is too thick or too thin.

Solution  

To avoid inaccurate folds or crushed boxes, operators need to regularly adjust the folding guides to ensure that they are perfectly matched to the box size. It is also important to use the right material, whether it is too thick or too thin, to avoid folding problems. In addition, the adjustment of the folding pressure is also critical to the quality of the folds. Too much pressure can crush the box, while insufficient pressure can prevent the fold from forming. Regular adjustment and calibration of the folding system will ensure that it is working at the correct pressure.

Box size mismatch

If the size of the box does not match the design specifications of the cartoning machine, it is very easy for the box to jam or fail to be loaded smoothly during the production process. Most of the time, this problem is caused by improper selection of box sizes or failure to adjust the molds in time.

Solution  

Ensuring that the box size matches the product specification exactly before production is the first step in solving this problem. If the product specification changes, the mold needs to be adjusted to the new size as well. In addition, the parameter settings of the cartoning machine need to be adjusted accordingly for different boxes to ensure that no jamming occurs during production.

Automation system failure

In an automated production line, an automatic cartoning machine relies on the precise operation of the automation control system. If the automation system fails, for example, if the sensors fail to sense the position of the product or box, the cartoning process will be interrupted.

Solution  

Keeping the automated cartoning machine system in good operating condition requires regular calibration of the sensors to ensure that their sensitivity meets requirements. Secondly, regular maintenance and software updates of the automation control system are required to prevent the equipment from functioning properly due to system jamming or program errors. If the equipment has been running for a long time, consider contacting the cartoning machine supplier to upgrade the automation control system to improve its operational efficiency.

Wear and tear of mechanical parts

As an important equipment in the production line, cartoning machine will inevitably produce wear and tear of mechanical parts after long time operation. This wear not only affects productivity, but also increases the failure rate of the equipment. If routine maintenance is neglected, the failure rate of the equipment will be greatly increased, affecting the production progress.

Solution  

Regular maintenance is an effective means of reducing mechanical wear. Operators need to develop a maintenance program for the equipment according to the equipment manufacturer's recommendations. Especially for the mechanical part of the lubrication, regular addition of lubricant can effectively reduce the friction between parts. For parts that have been significantly aged or damaged, need to be replaced in a timely manner, to avoid larger failures caused by small problems. At the same time, regular equipment testing and maintenance can also be found in advance of potential problems, to be resolved before the failure occurs.

How to choose the right cartoning machine

Choosing the right cartoning machine for your production needs is crucial, and the wrong choice can lead to decreased production line efficiency or impaired packaging quality. When choosing a cartoning machine, there are several key considerations:

Production Requirements

The speed of your packaging line is the first thing you need to evaluate. Choose the right cartoning machine equipment based on production volume and make sure it can match your daily, weekly or monthly production schedule. If you need high volume production requirements, then a high speed automatic cartoning machine will be a more suitable choice.

Product Type

Your product type will have a direct impact on the choice of cartoning machine. Different types of products, such as bottles, plates, bags, small instruments, etc., which are common in the pharmaceutical and food industries, require different cartoning designs or handling. Make sure you choose a cartoning machine that can accommodate products of all shapes and sizes.

Degree of automation

Choose different cartoning machines based on the automation requirements of the production line. Some companies may require a fully automated cartoning machine, while others may only need a partially automated machine. The higher the level of automation, the less manual intervention and the higher the productivity.

Floor space

If you have limited production space, the footprint of the cartoning machine is also a factor to consider. Modern cartoning machines come in a variety of designs, commonly vertical cartoning machines and horizontal cartoning machines. Vertical cartoning machines have a smaller footprint and lower capacity, while horizontal cartoning machines have a larger footprint and are suitable for batch and high-speed production needs.

After-sales service and support

It is important to choose a manufacturer that offers good after-sales service. Maintenance, parts replacement and operator training are all important factors in ensuring the long-term stability of your production line. Choosing a brand with a global service network and quick response capability will give you peace of mind.

Recommended Equipment: Rich Packing RQ-ZH-320W High-Speed Horizontal Cartoning Machine

If you're looking for an efficient and reliable cartoning machine, Rich PackingRQ-ZH-320W High-Speed Horizontal Cartoner is an excellent choice. Designed to meet the needs of high volume production, this machine has a very stable and excellent performance in terms of speed and performance, and is especially suitable for the pharmaceutical, food, and daily chemical industries.

Key Features:

High Speed Packaging Capability: This machine is capable of stable operation at speeds of up to 320 cartons per minute, making it ideal for high-intensity, high-volume production lines.

Versatility: RQ-ZH-320W high speed cartoning machine is able to handle a wide range of products of different shapes and sizes, which is suitable for the packaging needs of many industries. Such as pharmaceuticals (tablets, capsules) aluminum-plastic plates, soft double aluminum, flexible tubes, granule bags, ointments, soft bags, bottles of medicines, electronic cigarettes, face masks, facial cleansers, and other types of products for automatic cartoning.

Stability and Reliability: With its high quality components and advanced design, this high speed cartoning machine maintains stability even during long hours of operation, reducing breakdowns and maintenance needs.

Convenient operation: The touch screen control system and intelligent automatic adjustment function make the operation easier and reduce the reliance on manual labor.

High compatibility: Reserve the link port and sensor to form an automatic packaging line, which can be connected with automatic counting line, wrapping machine, blister packaging machine, 3D transparent film packaging machine, etc. to form a packaging line.

The RQ-ZH-320W is a machine that combines speed, precision and versatility to effectively increase the efficiency of your production line and ensure that every product is packaged with high quality. If you're looking for a cartoning machine that meets the demands of efficient production, Rich Packing RQ-ZH-320W is a reliable choice.

Cartoning machines play a vital role in modern production, but proper functioning of the equipment requires regular maintenance and troubleshooting. Understanding the common problems with cartoning machines and how to deal with them can help you minimize downtime and increase productivity. Armed with these tips and tricks, you can more comfortably deal with the challenges that cartoning machines encounter in actual production and ensure the efficient operation of your production line.