Box Forming Machines: Benefits, Types, and How They Work

Introduction to Box Forming Machines

Box forming machines, also known as box erectors or trayformers, are essential equipment for companies that manufacture corrugated boxes, cartons, trays, and other shipping containers. These machines take flat corrugated sheets and form them into assembled boxes ready for packing. Box forming technology has evolved over the years to become faster and more efficient at setting up boxes.

Types of Box Forming Machines

There are two main types of box forming machines:

• Tray formers - Tray formers, as the name suggests, are designed specifically to form trays. They are best suited for making open trays without lids. Common applications include forming shelves for retail displays or trays for food packaging.

• Box erectors - Box erectors can form all styles of boxes including regular slotted containers (RSCs), full overlap boxes, half slotted containers (HSCs), double wall boxes, and die cut boxes. They have the flexibility to run a wide range of box sizes and depths.

Box Former Components

The key components of a box forming machine include:

• Feeder section - Automatically feeds flat corrugated sheets into the machine.

• Prebreaking unit - Scores the sheets to facilitate bending.

• Forming section - Folds the sheets into box form.

• Gluing unit - Applies glue to form the joints of the box.

• Compression section - Presses the flaps together to seal the glue joints.

• Counter-ejector - Ejects formed boxes and counts production.

Benefits of Automated Box Forming

Automated box forming machines provide several advantages over manual box assembly:

• Higher speeds - Mechanical box formers are significantly faster than manual setup. Speeds of 15-25 boxes per minute are common.

• Consistency - Machines fold boxes identically every time for better quality and appearance.

• Lower costs - Less labor is required compared to hand folding. Increased throughput also lowers the per box cost.

• Flexibility - Quick changeover times allow handling short runs and frequent box size changes.

• Safety - Automation increases safety by reducing repetitive motion injuries.

How Box Forming Machines Work

Understanding the step-by-step process of how box formers work provides insight into their speed, flexibility, and reliability:

1. Sheet feeding - Flat corrugated sheets are automatically fed one-by-one from a pallet or stack into the feeding mechanism. Precise feed control prevents misfeeds and double feeds.

2. Scoring - Rotating scoring wheels make crease lines at precise locations on the sheet where bends will occur. This prebreaking allows tight, crisp folds.

3. Glue application - Cold glue is applied by rollers or spray nozzles onto the tabs or flanges that will form the box joints. Proper glue coverage ensures secure bonds.

4. Forming - Forming plates or mandrels fold the sheet into the box shape progressively at each section. Top and bottom flaps are folded last.

5. Compression - A compression section presses the box flaps together to seal the glued joints tightly and square the box shape.

6. Count & eject - Counters record box production totals. Ejectors separate finished boxes from one another for smooth delivery.

Box Former Settings

Box forming machines have adjustable settings to accommodate different box sizes and styles. Common settings include:

• Sheet size

• Depth stroke

• Glue application points

• Scoring locations

• Forming plate position

• Compression depth

Quick-change capabilities on modern machines allow operators to switch between box sizes in just minutes without requiring mechanical adjustments.

Advantages of Box Forming Machines

Investing in box forming equipment has many benefits beyond basic automation. Key advantages include:

1. Improved Productivity & Throughput

Box formers produce completed boxes at rates from 15 to 60 boxes per minute depending on machine speed and box size. This allows one operator to accomplish the work of several manual assemblers. The machines can run lights out for high-volume production.

2. Enhanced Operator Ergonomics & Safety

Box forming machines eliminate the need for repetitive bending, folding and taping. This greatly reduces muscle strain and fatigue compared to manual box setup. Automation also minimizes safety risks associated with cutting blades, hot melt glue, and extended periods of standing.

3. Reduced Labor Costs

With automated box forming, fewer operators are needed to achieve required production levels. Labor becomes a much smaller percentage of overall packaging costs. Savings can be redirected towards growth, quality improvement, and other initiatives.

4. Consistent Box Quality & Appearance

Programmable box formers fold and seal boxes identically every cycle. Boxes have crisp, sharp corners and evenly sealed joints. This consistency improves presentation and customer satisfaction compared to hand folding.

5. Faster Changeovers & Reduced Downtime

Quick-change box formers allow switching between box sizes and styles in only a few minutes with no manual adjustments needed. This facilitates economical short runs and rapid new product introductions. Changeovers are simple enough for operators to perform.

6. Space Savings

Compact box forming machines have a small footprint that saves valuable floor space. Some systems can be configured for vertical or horizontal sheet feeding to best fit production layouts and available plant space.

7. Sustainability Benefits

Right-sized box forming minimizes waste by ensuring boxes are made to exact dimensions needed for each product. Formed-to-fit boxes also reduce the need for void fill and dunnage materials. This supports sustainability objectives.

Types of Boxes Formed by Box Forming Machines

Modern box formers can produce every major style of cardboard box. Common box types formed include:

Regular Slotted Containers (RSCs)

RSCs are the most common box style. All panels are the same size and top and bottom flaps interlock when sealed. RSCs stack efficiently and work for many applications.

Half Slotted Containers (HSCs)

Half slotted containers have a half-depth front flap rather than a full flap. They are ideal for products requiring front access like books and electronics.

Full Overlap Boxes

Full overlap boxes have flaps that fully overlap on both top and bottom. This creates extra stacking strength ideal for heavier products.

Double Wall Boxes

Double wall boxes have an inner and outer layer for added strength and insulation. They provide excellent protection for fragile contents.

Die Cut Boxes

Die cut boxes have custom shapes, cutouts, and perforations for specialized applications and unique packaging. Common for mailers, displays, and inserts.

Trays

Trays have no lid and are formed with an open top. Often used for retail displays, electronics, and food packaging.

Conclusion

Box forming technology enables efficient, automated setup of corrugated boxes for all industries. Modern box formers are highly flexible machines that can readily switch between box sizes and styles with minimal changeover. They deliver improvements in productivity, quality, ergonomics, and costs compared to manual box making methods. With speeds up to 60 boxes per minute, box formers represent a smart packaging automation investment.

FAQs

What are the main types of box forming machines?

The two main types are tray formers and box erectors. Tray formers make open trays while box erectors can form all box styles including RSCs, HSCs, full overlap boxes, and more.

How fast can box forming machines run?

Box forming machine speeds typically range from 15 to 60 boxes per minute depending on the machine model and box size being run.

What safety benefits do box formers provide?

Box forming machines improve safety by eliminating repetitive motions that can cause injuries. Automation also reduces risks from cutting blades, hot melt glue, and extended periods of standing.

How quick are changeovers on modern box formers?

Quick-change design allows box size changeovers in just minutes without mechanical adjustments. Operators can easily handle changeovers.

Can box formers make custom boxes?

Yes, with the use of custom dies, box formers can produce boxes with unique shapes, cutouts, perforations, and other special features.