Case & tray packing has evolved significantly over the past 50 years. While product continues to be placed into a corrugated case or tray as a method of protecting and containing product until it reaches its final destination, the technology and method of placing product into the case or tray has dramatically changed.

Initial case & tray packing automation started with cam-driven mechanical machines with supporting functions driven by pneumatic cylinders. These machines were heavily reliant on mechanical engineers laying out cam profiles and related linkage to achieve desired motions. The brains of the machine derived from relay logic, which was charged with determining if and when a function would be initiated. The cams were driven by a line shaft that typically ran the length of the machine with a clutch supporting the drive motions and brakes holding position. The components were protected by a torque limiting device that would stop the machine when a defined level of resistance was achieved. While these devices protected the components, it was usually at the sacrifice of the product.

In the late 1990’s and early 2000’s, electromechanical automation started to gain acceptance in the packaging market and opened a significant opportunity for machine builders. The introduction of servo-driven functions stressed the importance of collaboration between mechanical and electrical engineers throughout the design process.

Packaging machines were becoming “smart”, providing a boost to their capability and flexibility. The introduction of servo motion allowed direct drive applications, eliminating the need for a physical line shaft to drive functions. Thanks to servo motion, machines could communicate through digital technology and timing through the digital line shaft. Today, cam profiles can be changed in minutes versus days. Servo driven motion allows improved timing of individual functions, resulting in maximizing overall machine performance and flexibility.

While servo driven functions and digital technology has significantly impacted the case & tray packing industry, technology continues to evolve. The digital era changes daily and will continue to drive case & tray packing technology to ever increasing capabilities.

Modern Product Packaging With Douglas Machine

With the increased flexibility that servo driven motion provides machine builders, there is an expanding opportunity for creativity in how product is placed into a case or tray. Through the design process, Douglas Machine engineers look to combine functions while increasing flexibility. The ultimate outcome of this process is a machine that exceeds our customer’s demands for safety, reliability, flexibility and ease of operation. With the ever-changing marketplace, machines need to be flexible enough to be modified for future product demands and run at the same reliability that the machine was originally purchased to run.

From mid to high-speed case packing, Douglas delivers innovative design, cutting edge technology and precise product control to create the most effective solution for your application. Below is a brief summary of Douglas case and tray packer solutions:

• Axiom® IM – Intermittent motion case & tray packer that combines the ultimate in dependable high speed operation with gentle product handling, servo controlled precision and unparalleled flexibility. The open frame modular design platform, innovative infeed technologies and simple, menu-driven changeovers allow effortless adaptation to evolving and uncertain product life cycles. Offers industry leading performance in a compact, low maintenance package.
• Axiom® ARC – The Axiom ARC manages large size ranges and flexible, odd-shaped packages while controlling product through the entire load cycle. Servo functions reliably and accurately pack cartons, bottles, cans, jars, jugs and more using innovative infeed technology and high speed case loading methods with precise product control.
• Axiom® DL – Streamlined performance as dual paddle metering is used to directly load product onto the case or tray blank to minimize unnecessary components and increase production efficiency. Continuous motion case squaring and sealing produces squared cases at high speeds.
• Invex® IM – Conveniently flexible and loaded with experience-based design, these case & tray packers bring a higher level of performance to mid-range applications. Its simplistic combination of design, positive drive technology and control avoids compromise and maximizes operation.
• TriVex® RL & RLi – Packed with performance enhancing technology, this compact top load case packer offers automated robotic case & tray packing solutions to accommodate the unique demands associated with handling bags, pouches, cartons, trays, tubs, cups, cans, bottles and overwrapped products. Maximized flexibility provides efficient loading of products into almost any style of pre-erected top load case or tray. TriVex RLi offers the unique ability to seamlessly erect, load and seal top load cases with one compact machine. Optimum solution for the high demands associated with 3-shift production, frequent format changes and high efficiencies.
• TriVex® SL & SLi – These versatile and innovative solutions are ideal for the demands of the growing retail ready market. This robotic top load case packer meets market needs for lines requiring products to be packed vertical in the case and lines requiring both vertical and flat pack product orientations. Vertical pack configurations produce retail ready display cases with 1 or 2 product facings. With a quick and simple changeover it packs pouches and flat bottom bags laying flat in the case with 2 or 3 products per layer. The TriVex SL & SLi use a dual SCARA robotic solution uniquely combining the functionality of a product infeed, pack pattern collation and case loading functions into one mechanism.
• TriVex® CLi – The ideal case packer for Individual Quick Frozen (IQF) products such as non-free flowing frozen potatoes and vegetables, as well as pillow and gusseted bag product applications requiring flat and vertical bag orientations. The integrated case erector, upright and flat pack flexibility and large size range meet market demand for case packing both retail and food service bags. The convertible cassette pivots to easily reposition to horizontal or vertical mode which reduces parts and changeover time.
• Ascend™ Bottom Loader – Compact, fully automated machine designed to load flexible and complex shaped products into cases. Best suited for tubs, cylindrical and heavy products, the Ascend will meet your specific packaging requirements and deliver the ideal solution for your low speed packaging needs.
• Contour™ – Tray packers available as stand-alone units or fully integrated systems with a Contour™ shrink wrapper, for tray or pad applications. These versatile systems offer exceptional performance and the best finished package appearance and durability available. Productivity is further enhanced with the addition of our patented Smartrak® II infeed system which eliminates product bridging and removes the gaps that compromise pack pattern accuracy and continuous product flow.

Contact Douglas to discuss solutions or check out our Douglas Corporate Capabilities brochure to learn more about our products and services.

Investing in a cartoner can be a daunting task if you don’t know what to look for, or where and how to start the searching process. The desire to purchase a cartoning machine is typically driven by the desire to package your product more efficiently, improve ergonomics and improve the aesthetics of your package. At Douglas Machine, we suggest that you analyze your present process as well as your long-term goals for process improvement. The decision to automate your cartoning operation should be done with the objective to also minimize the material cost of the package. Justifying the cost of a cartoner is a one-time event. Reducing the cost of material will pay dividends over the long run.</p Whether you are seeking a semi-automatic carton sealer or a totally automated product handling and cartoning system, knowing your present costs and your return on investment goals can easily set the stage for creating a budget range that should prove economically feasible. You’ll want to be sure to also carefully consider your product characteristics, your organization’s capabilities in technical expertise, required machine speed, delivery, changeover time, parts availability and service capabilities. A robust design is needed to withstand the production environment. The machine must be flexible and customizable to meet your current and future packaging requirements. Supplier experience and reputation are also important factors. Ensure that your cartoner supplier can provide line integration knowledge and technical support throughout the life of the machine, not just from the point of contact through installation.

What is a Cartoner?

A cartoning machine or cartoner, is a packaging machine that opens cartons from a pre-glued side seamed blank.  It erects the cartons for manual or automatic product insertion and then closes and seals the carton with tuck or glue.

Types of Cartoners

A horizontal or end-load cartoner pulls a carton blank from the magazine, opens it into carton flights horizontally and fills it either manually or automatically. A single product (tray or bag for instance) or multiple products can be collated and loaded through the open end of the carton by pushing them in manually or using an automatic barrel cam loader. Once loaded, the end flaps are folded and tucked or glued, depending on the application. The finished carton is discharged to downstream operations. A vertical cartoner pulls a carton blank from the magazine and opens it into carton flights vertically. Single or multiple products can be collated and loaded through the open end of the carton manually or automatically. Once loaded, the end flaps are folded and tucked or glued, depending on the application. The finished carton is discharged to downstream operations.

Industries that Benefit From Cartoners

Douglas cartoners are specifically designed to our customers’ product. Some of the industries that we proudly serve include:

• Frozen, chilled and dry goods food
• Beverage
• Craft Brew
• Pharmaceutical
• Household/Industrial
• Paper & Textiles
• Consumer & Industrial Durables
• Personal Care

Cartoners from Douglas Machine Inc.

Featuring servo technology and adaptable platforms, Douglas delivers leading-edge cartoning solutions that result in greater throughput, less waste, and enhanced production efficiency for a wide variety of product types and sizes. Douglas cartoner offerings include:

Vectra®

Compact and cost-efficient design saves valuable production floor space and allows for generous accessibility to setup and load areas. Reduced and faster changeover points increase uptime to deliver maximum performance. The Vectra easily accommodates varied size ranges and pack patterns for frozen goods in bags or trays, chilled and dry goods food applications. With unmatched adaptability and exceptional efficiencies in a compact cartoner, the Vectra platform offers a continuous motion servo controlled cartoner capable of maximized performance in a variety of applications. The open design allows for generous accessibility to setup and load areas as well as providing easy and efficient access for cleaning.

Vantra™

Compact and economical low-to-mid speed intermittent motion cartoner is capable of producing both cartons and trays on a single machine. Douglas’ innovative Vantra IM is a compact, economical intermittent motion cartoner with the flexibility to setup, load and, close cartons and trays at speeds up to 55 per minute within a single platform. This versatile cartoner can be integrated with various in-feed options to gently handle cans, bottles, cartons, bags, flat-flow wrapped product and more, including applications requiring multiple manipulations. It is designed with a hygienic sheet metal frame and standoff bearing mounts to accommodate the customer’s specific washdown requirements.

Spectrum®

Our Spectrum model is a mid-to-high speed multipacker available in mechanical and/or servo based platforms. It is capable of reaching speeds of up to 250 cartons per minute and is specifically designed for loading cans and/or bottles into 4-24 count cartons. The Spectrum is built tough for less downtime, high efficiencies, and low operating costs in the most demanding environments. The Spectrum uses electronic motion control to multipack soft drink, brewery, dairy or nutraceutical products.

Apex™ 

The Apex offers high-speed, innovative sleeving solutions for wraparound, drop-through or neck-through sleeve configurations. Apex sleevers offer class-leading paperboard solutions for a wide range of products, sleeve styles and pack configurations. With speeds up to 300 sleeves per minute, easily adaptable product handling options, advanced servo technology and heavy gauge stainless steel construction, Douglas delivers a non-stop powerhouse of performance, versatility and reliability.

Douglas Service and Support

We work hard to ensure you receive a customer-driven experience from the first point of contact through the life of your machine. Douglas Technical Support provides unparalleled in-house and field technical support, available 24 hours a day and 7 days a week. Douglas’ Regional Technical Support program was established in 1998 to provide local and immediate support by strategically locating technical support technicians throughout the United States. These technicians have skills to provide support for emergency issues, routine maintenance, audits, training and courtesy visits. In every aspect of your relationship with us, our friendly and skilled employee owners are 100% committed to provide you with valuable and effective collaboration, innovative solutions, responsive support and more. Contact us today to discuss solutions for all of your cartoning application needs.

The craft beer market continues to explode. Competition in this industry is tough. There were 6,000 breweries in operation during 2017, with 98 percent of them small and independent craft brewers. People are drinking a greater volume of craft beer than ever before, but they’re also drinking a wider variety of different types of craft beer.

As a craft brewer, you want to expose craft beer drinkers to as many types of your beer as possible. One of the growing packaging trends is assembling variety packs that serves as a showcase for a brewery’s products. Consumers love to try out different flavors and makes of beer, especially in this form of packaging as the commitment is limited. Having 2-3 of each type of beer allows for beer drinkers to enjoy the novelty of drinking seasonal or newly made beers, without committing to buying an entire case of them.

How can craft breweries attract attention from consumers in such a crowded marketplace? Through secondary packaging.

A company’s brand and packaging tell a story to the consumer. Consumers are looking to the breweries, and the packaging, to articulate how it tastes while also defining what kind of experience they will have while drinking the product. Craft beer manufacturers can spend a lot of money to visually convey that message to their consumers. At Douglas, we understand that your brand matters. You have already invested greatly in the brand message, image and competitive edge. Now it is time to invest in equipment capable of creating the best secondary package to convey your brand.

What is Secondary Packaging?

Secondary packaging is generally the front line in brand recognition. It is the first thing a customer sees. Primary packaging is the layer of packaging that is in immediate contact with the product. Primary packaging would be considered a singular beer, whereas secondary packaging would be a case of beer.

Beyond recognition and first impression, secondary packaging must also be able to contain and protect the individual product and the primary packaging, as it travels from the plant to the customer’s refrigerator.

Dig a little deeper into secondary packaging and learn more about the important role it plays by reading our blog “What is Secondary Packaging?”.

The Shipping and Handling of Beer

The right secondary packaging solution will protect beer during its journey from the brewery to retailers and eventually to consumers. Damaged packaging most likely will not do as good of a job protecting the product. Damaged packaging can also give consumers a bad impression of a product and its brand. Consumers are very selective when making purchases and often times the damaged packages tend to be the last to remain on the shelf in a store.

When the product or primary packaging is loose inside the secondary packaging it was shipped in, it can also give the consumer a negative view of the company’s brand. It could be the result of sizing issues or lack of protection inside the container that allow it to rattle around inside the container. These issues not only impact this one-time purchase, but it can also make a consumer think twice about purchasing another product from that company in the future.

Companies can create a positive experience for their consumers through packaging. Using multiple layers of packaging that separate the components protects the product while it’s in transit. It can also help focus the consumer’s attention on one component at a time, helping to create an appreciation for each part. The company supports their quality product with a quality package for the product’s protection. Quality packaging also visually conveys product quality to the consumer.

Secondary Packaging Can Boost Your Beer’s Branding Efforts

Branding makes all the difference. When there are so many products to choose from in the market, standing out from the competition is a key driver of sales. Branding and shelf appeal can become the primary differentiator. The growth of craft beer has resulted in more engaging, premium and visually appealing secondary packaging throughout the beverage market.

To achieve the high-quality printed graphics beverage companies desire, secondary packaging suppliers continue to innovate and improve their offerings. To keep customers coming back to their brand, companies need to continually produce new products and new packaging.

Brand expression is vital. There is so much passion behind each brand and so much individuality. Packaging is what the consumer interacts with most. The package is the perfect way to convey that individuality and reach out and grab consumers. The stories behind the craft breweries resonate strongly with people. Stories of how the breweries started, how they operate, how they compete. These stories should be portrayed through the packaging and branding.

When considering packaging options, be sure to look into the crystal ball of packaging sizes (4, 6, 10, 12, etc.) and pick a machine that your brand can grow into. Since the market is ever-changing, it’s ideal if your packaging machine has the flexibility to accommodate those changes.

Secondary Packaging with Douglas Machine Inc.

With the craft breweries’ goal of promoting a brand and successfully protecting the brand packaging, Douglas Machine can partner with the craft brew industry by providing a wide range of secondary packaging types (shrink, carton, cases and more). Our adaptable platforms and leading-edge solutions result in greater throughput. Our ability to offer variety/rainbow pack capability along with innovative design, cutting edge technology and precise product control offer the most effective and flexible solutions for your application.

Douglas machines are built to sustain the industry rigors day after day without compromising your all-important brand in any way. In every aspect of your relationship with us, you will experience 100% commitment to a partnership that ensures your brand is represented with quality, integrity and pride.

Retail Ready Packaging (aka Shelf Ready Packaging) Trends

Large retailers, such as Walmart and Aldi, are encouraging suppliers to use retail ready packaging (RRP). The requirements of large retailers such as these two, are playing a big part in the growing trend of RRP within secondary packaging solutions.

What is Retail Ready Packaging (RRP)?

Retail ready packaging, also known as shelf ready packaging, is ready-to-sell secondary packaging. Primary packaging contains the product and secondary packaging protects the primary packaging. RRP is placed directly onto the shelf without the need for unpacking the inner contents. The shelf ready packaging market is fairly new, having started in the UK around 2006. There are many different types of RRP in the market today. Examples include pallet displays such as stacking trays and bins, sidekicks, end cap displays, as well as trays that sit on a shelf or counter. Retail ready packaging solutions which can be placed on the shelf are predominantly made of corrugated cardboard. Corrugated boxes, which represent more than 50 percent of total demand, will provide the strongest opportunities. In addition to corrugated cardboard, there are also plastic, reusable solutions.

Advantages of RRP

The top advantages of RRP can be summarized with one word: easy.

Easy to Open

Shelf ready packaging solutions are designed to open easily without any tools such as box cutters. They are also are engineered to be strong enough to hold up during transport without damage. After opening the packaging, it’s essential that the quality, integrity and appearance of the products are not affected.

Easy Shelf Placement

Product, content, versions, product barcode and expiration dates are printed to be clearly visible to provide for easy handling. Easy identification reduces placement error while stocking shelves. Handles integrated into the packaging can help store employees with shelf placement.

Easy to Replenish on the Shelf

Easy identification of product allows for a faster and more efficient stocking process. To be efficient, two shelf ready packages can be placed in-line on one shelf to maximize the space available and to avoid situations where products are out-of-stock. Since these packages are easier to open, it allows for easier and quicker replenishment when stock dwindles.

Easy Shop

To make it easy for both the retailer and the end consumer, the front panel typically represents the products included in the packaging and offers visibility of the manufacturer’s logo, thus improving product identification. Shelf ready packaging, in most cases, is designed brightly to attract the attention of customers. To create an easy shopping experience, the customer can easily remove the product from the packaging and it remains stable and visually appealing for the next set of customers, even in a half-empty state. The customer also can easily place the product back in the packaging if they don’t want it, without disrupting the shelf-appeal of the other products.

Disadvantages of RRP

When there are advantages, there are always disadvantages. A couple of disadvantages to shelf ready packaging include package stability and cost.

Package Stability

The more people that handle a package, the more likely it is to show wear and possibly break down. Package design and stability are very important considerations for packaging so it can withstand contact with multiple consumers. Extra time may be needed to design a package that can hold its original shape.

Package Costs

The cost of manufacturing a package that is displayed on a shelf is higher than packaging that isn’t customer facing. Brand owners must invest in presenting their brand to consumers. Four-color printing, with vibrant graphics, will compete for consumer attention, and will usually show a return on the investment. It is important to note that while retailers often drive packaging specifications, they most often are not the ones absorbing the cost. Brand owners are often left to absorb the cost increase for package innovation.

Retail Ready Packaging Trends

Eco-Friendly Packaging

Eco-friendly materials can make production less expensive and more efficient, and will also appeal to environmentally-conscious customers. This type of packaging uses minimal material and can be recycled.

Short-term Package Designs

The number of products in stores is growing and packaging is being updated more frequently than ever before. In a competitive marketplace, brand owners are fighting for their package design to be noticed. Research indicates that consumer’s attention span has dropped from 12 seconds to 8 seconds. This data is critical for brand owners and retailers, driving many innovations in marketing.

Market Growth

According to a study conducted by Smithers Pira, the market for retail ready packaging continues to increase and is expected to grow on average by about 4% annually until 2021. Shelf ready packaging is expected to reach $82 billion globally in 2021.  

Secondary Packaging from Douglas Machine Inc.

With the ever-changing and fast moving trends of retail ready packaging, retailers can look to Douglas Machine to find their secondary packaging solutions. Our mission to enrich lives by providing differentiated packaging automation and services, is the foundation of our drive for innovation and the principle behind our hard work and dedication to provide solutions to meet industry needs and trends. To start, our TriVex RL & RLi is the most versatile top load system in the industry and the TriVex SL & SLi is the simplest retail ready case packer on the market … and that’s only the beginning. Contact us today to learn more.

Summit Brewing Co. in St. Paul has served both craft beer and its community since 1986. To Summit, it’s not just a priority to brew fine, hand-crafted beer, but also to give back to the community that has supported them throughout the years. The company feels that great beer is even better when it’s shared with family and friends. 2016 marked a special milestone for Summit as they celebrated 30 years of creativity, consistency and community. A milestone such as this deserves to be celebrated in a grand way. To commemorate the anniversary, Summit aimed to offer its loyal consumers a new packaging choice: a 30-pack of its canned craft beer. 

Canned Beer vs. Bottled Beer

Despite the old industry adage that premium beer comes in bottles and less-quality beer comes in cans, the market is proving otherwise. Summit decided to do its own taste-test to dispel this myth and found no difference in the quality of beer that comes from a bottle versus a can. Although craft brewers have traditionally chosen to use bottles, many are making the transition to cans. Cans have become accepted by craft beer consumers in large part because of their convenience. Enjoying canned beer in recreational areas such as beaches and ballparks is much easier, and safer, for consumers than fragile bottles. Cans also provide craft brewers the opportunity to expand their distribution.

The Challenge: Packaging 30 Cans in One Carton

To meet the growing market of canned craft beer, Summit introduced its can line in 2014 and began producing six-packs of its craft beers. Even from the start, offering 12-packs, or larger packs, was a primary focus of Summit’s plan. The company aimed to give its consumers what they wanted — and more. Through networking channels, Summit received a recommendation to connect with Douglas Machine Inc. They were told that Douglas is an employee-owned company in Alexandria, Minnesota who have long maintained a reputation for excellence in providing outstanding secondary packaging solutions for their customers. When Summit learned that Douglas uses the phrase “More. It’s who we are.” to describe its innovation and services, it seemed to align with their can line needs, so they made the call to Douglas. Initial meetings at Summit’s facility proved successful and quickly turned into an in-person visit at Douglas to view the Vantra IM cartoner. Looking for a compact machine with big capabilities, Summit wanted to get a sense of how the machine operated. To be a good fit, the machine needed to carton packs of beer that contained 12, 24, and 30 canned beers in each case package.

The Vantra IM Cartoner

The Vantra IM cartoner’s flexible size range was exactly what Summit was looking for to solve their packaging challenge, giving the company the ability to run the variety of carton sizes it required to fulfill the markets demands, and to best serve their customers. The Vantra IM’s compact size proved to be a perfect fit for the plant. With the new cartoner, cans are delivered in mass to a recirculation table that creates and delivers lanes of product to the cartoner. Cans then are loaded into cartons with a high-speed loader, and flaps are tucked and glued. Cartons are produced at speeds up to 50 per minute, a range matching the needs of many craft brewers. For the craft beer industry, not many quality machines are offered in this range. The tool-less changeover optimizes production time, keeping product moving. The Vantra IM met Summit’s needs across the board.

Meeting the Deadline

Although machine specifications and installation discussions were underway, Summit realized that the clock was ticking away to make their August anniversary date. Installation needed to happen much sooner than anticipated or the 30-pack would not be produced in time for the grand appearance at the anniversary celebration. With Summit’s goal in jeopardy, Douglas and Summit worked together to adjust the timeline, and Douglas made it happen. Additionally, Summit received an unexpected benefit — a smooth relationship between Douglas and the conveyor vendor. Often times there’s a lot of follow up when integrating equipment. Because a relationship already was established between Douglas and the vendor, it made the entire process easier. The result was a seamless integration from start to finish. A benefit that Summit, and any producer, can appreciate.

The Result

“I’ve bought and installed every piece of machinery in this brewery, and this was by far the best startup I’ve ever been through,” says Tom Thomasser, chief operations officer at Summit. “Our efficiencies exceeded expectations from Day 1. I would definitely buy another Douglas machine.” The Vantra IM’s performance and capabilities helped Summit meet its 30-pack goal. With an expanded capability to run cans and package a variety of carton sizes, the increase in market reach will be substantial, giving Summit its more. For small occasions or large gatherings, 12, 24, and 30 packs ensure everyone gets to enjoy a Summit beer. Want to discover how Douglas Machine Inc. can help solve your packaging challenges? Contact us today.