Any seasoned packaging technologist, plant engineer, or engineer probably knows the ins and outs of the standard secondary packaging line. For those of you who are just starting out or who want to get a benchmark for how your packaging process is performing, this is a good place to start. Secondary packaging has to do with the protection and display of the primary package, which contains the product. There are a variety of secondary package formats to choose from, but most will require similar equipment needs.
First off, you’ll need to erect the secondary package. Whether you are erecting cartons, cases, trays, or retail ready packages, you’ll need what is commonly referred to as an erecting machine. This formed unit will be transferred to the second machine in the secondary packaging process, commonly referred to as a loader or packer.
There are a variety of ways to load your product into the formed secondary package at this point (commonly top load or side load). The takeaway from this step is that you need a machine to place your product into your erected secondary package.
Next the secondary package will be transferred to a machine that will seal (or close) the secondary package. The output from this machine - referred to as the sealer or closer - will be sent off to the final packaging machine needed before distribution to retailers.
The final machine in the packaging process is a palletizer, which stacks up the products and maximizes shipping efficiency and package durability throughout distribution.
There are plenty of add-ons offered to improve secondary packaging equipment, which are customized to the product running on the line, but the purpose of the four major machines remain consistent for most secondary package lines.
It’s important to ensure your equipment is well integrated and operating efficiently. Purchasing flexible equipment that is compatible with more than one case and package design gives you more options for packaging designs and equipment functionality without having to invest in more machines or equipment lines.
Our most popular carton packaging line commonly includes the Trayfecta® S Carton & Case Erector and our F Series Sealer. These two machines give producers the ability to run multiple carton, case, tray, and retail ready package formats with a single Trayfecta machine with no added cost! The additional freedom these two machines help plant managers future proof their operation.
You’ll want the newest of Delkor’s Trayfecta formers when your product comes in pouches and bags. The Trayfecta G Series uses a robotic gantry system to erect and place the tray or case in any orientation on the conveyor belt, and it ensures a precise forming of the secondary package. The rest of this line splits off into two directions, based on the size and speed you are planning on running with your products. For heavy products, the LSP Series Case Packer is an easy choice. It packs pouches and bags up to ten pounds with top load vacuum pumps! For smaller products, our MSP-m Case Packer is quite popular. The MSP-m is a mid-speed top load case packer for bags and pouches that runs comfortably at speeds up to 200 a minute. To finish off both pouch and bag packaging lines, the Capstone F Sealer is recommended. This compact carton, case, tray, and retail ready case sealer is compact, versatile, and lightning fast. For additional efficiency, the Robotic Palletizer is recommended. This will stack up your secondary packages so they’re ready to be wheeled out and placed on shelves!
When it comes to secondary packaging, packages are constantly evolving. We've created machinery that can keep running your new packages without missing a beat. Whether you are running trays and wish to switch back to Spot-Pak®, or whether you have a new larger box on your cartoning line, you don't need to worry! Our engineers have designed our machinery to be adaptable and flexible enough to run a wide variety of products! The last thing you want is to be limited by a machine you added in order to boost plant efficiency!
This equipment layout does differ entirely for shrink wrap packaging, which tends to be performed within a single shrink tunnel packaging machine. There can be an erecting unit included with this secondary package format, if the package is going to be tray shrink. For Spot-Pak pad or shrink bundling applications, there is no need to have an erecting machine or sealing machine attached to this line.