In 2023, PepsiCo’s net revenue worldwide amounted to about 91.47 billion U.S. dollars, a testament to their massive production scale. One of the key components of their success is their use of both wrap-around and regular case packers to streamline packaging. PepsiCo relies on these case packers to ensure efficiency, maintain product integrity, and keep their global supply chain running smoothly.
Let’s explore the strengths and weaknesses of both types of case packers, helping you find the best fit for your business operations.
What Are Wrap-Around Case Packers?
Wrap-around case packers are machines tailored to streamline the packing process in manufacturing and distribution. These machines take a simpler approach by wrapping a flat cardboard piece around your product, forming a custom-fit box with just the right amount of packaging material. This method is not just about keeping your product snug and safe; it’s about doing it efficiently and sustainably.
How Do Wrap-Around Case Packers Work?
Imagine a process that starts with a flat piece of cardboard that enters the machine ready to embrace your product. Here’s how it works:
- Positioning the Product: Your item or a group of items is placed on this cardboard by a robotic arm, precise and gentle.
- Wrapping Up: As the product and cardboard move together along the line, the machine folds the cardboard around the item. It’s like watching a gift being wrapped neatly in real-time.
- Sealing the Deal: The edges of the cardboard are then glued or sealed, securing the product in a perfectly tailored package.
This all-in-one approach not only speeds up the packaging process, but also cuts down on the labor and space you’d typically need. It’s efficient, reduces waste, and can save a good chunk of change in terms of operational costs.
Case Study: Custom Wrap-Around System for Heavy Rolls of Copper Coils
One standout example of our technology in action is the custom-designed system we developed for packing heavy rolls of copper coils. Engineered to manage even the most cumbersome and awkwardly shaped products, this system highlights our adaptability and expertise in automation.
This system was specifically created to ensure that each copper coil is securely packed with unparalleled precision. It minimizes material waste and maximizes protection, perfectly embodying our commitment to innovative, efficient, and specialized packaging solutions. We’ve designed this machine to cater precisely to the unique demands of handling and shipping heavy industrial materials.
Benefits of Wrap-Around Case Packers
Efficient Material Use and Minimal Waste
Wrap-around case packers are designed to be resource-efficient, using the exact amount of cardboard needed to securely package products. This precision cuts down on material waste significantly, making it a sustainable choice for businesses conscious about their environmental impact.
Cost-Effectiveness in Shipping and Storage
The compact nature of the packaging produced by wrap-around case packers means more products can be shipped at a lower cost. Additionally, the need for less storage space for blanks translates into further savings, optimizing your total cost of operations.
Reducing Operational Costs
By streamlining the packaging process, wrap-around case packers minimize the need for manual labor and reduce the time spent on each packing stage. This efficiency not only speeds up production, but also lowers day-to-day operational costs, making these machines a cost-effective investment in the long run.
What Are Regular Case Packers?
Regular case packers, often known simply as case packers, are versatile machines used across various industries to automate the packing process. These systems are designed to handle pre-formed cases, efficiently filling them with products through top, bottom, or side loading methods.
Different Types of Regular Case Packers
Regular case packers come in several configurations, each tailored to meet different production needs and operational scales. Whether you need a machine that can handle delicate products or require a robust system for heavier items, there’s a case packer built to meet your requirements.
- Modular Systems: These allow for customization and scalability, adapting to production needs as they grow.
- Erector/Loader/Sealer Combinations: Combine multiple stages of the packing process into one streamlined operation, enhancing efficiency.
- Top, Bottom, and Side Loaders: Depending on the product and packaging type, these machines can insert items from different angles to best suit the item’s dimensions and packing needs.
Examples of Various Models
- PKR GANTRY (Modular Top Load)
- This modular top-load case packer uses a gantry robot to place products into the case, making it ideal for industries where precision and gentleness are key. Its adaptability makes it perfect for packing jars, cans, bottles, and clamshells.
- PKR DELTA (Modular Top Load)
- The PKR Delta is a modular pick-and-place cell that automatically top-loads lay flat pillow bags, stand-up pouches, top-sealed cups, clam shells and more into cases or trays using a Delta Robot. With gentle product handling by vacuum or mechanical means, it ensures product integrity and packing consistency. Its modular design allows for seamless integration into existing production lines or as part of a complete packaging system.
- BOXXER ALL IN ONE (Top Load)
- Combining case erecting, product loading, and case sealing into one unit, this all-in-one top loader enhances the speed and efficiency of the packing process. It’s particularly effective for operations that require quick turnaround without sacrificing packaging quality.
- BOXXER ALL IN ONE (Bottom Load)
- Similar to its top-loading counterpart, but designed for different packaging dynamics, this machine loads products from the bottom, providing a secure packing solution for heavier or more stable items that need support from beneath.
- BOXXER All-In-One Case Packer (Side Load)
- The BOXXER All-In-One with Side Load offers a specialized side-loading mechanism, making it perfectly suited for medium-sized items such as toy cases. This feature ensures precise placement and secure packing, enhancing both safety and efficiency.
Benefits of Regular Case Packers
Flexibility in Operations
Regular case packers offer unmatched flexibility in handling a variety of product types due to their ability to work with pre-formed cases. This adaptability makes them an ideal choice for industries with diverse packaging needs, enabling quick changes in production lines without significant downtime.
Continuity in Production
One of the significant advantages of regular case packers is their capability to continue production manually, should the machinery experience a failure. This ensures that your operations can keep running, reducing potential losses and maintaining productivity even under less-than-ideal circumstances.
Customization for Specific Needs
Regular case packers come with extensive customization options to fit the specific applications and spatial requirements of your facility. Whether you need a compact design for a small space or a specialized setup for unique products, these machines can meet your exact needs.
Drawbacks of Regular Case Packers
Higher Initial Costs
While offering numerous advantages, regular case packers typically involve higher initial costs due to the need for pre-formed cases. These costs can be a consideration for businesses evaluating their long-term investment in packaging machinery.
Increased Storage Needs
The use of pre-formed cases means that more storage space is required compared to other packing methods that use flat or less bulky materials. Planning for additional storage can be a critical factor when deciding on this type of packaging system.
Operational Overhead
Operating regular case packers can lead to higher ongoing expenses. The comparative analysis of operational overhead, including maintenance, storage, and materials, should be carefully considered to ensure that this solution aligns with your company’s financial and operational strategies.
Comparative Analysis: Wrap-Around vs. Regular Case Packers
| Feature | Wrap-Around Case Packers | Regular Case Packers |
| Forming Style | Uses flat cardboard, wrapping around the product. | Utilizes pre-formed cases, filled via top, bottom, or side loading. |
| Efficiency | High efficiency with minimal waste. | Moderate efficiency; depends on pre-formed case design. |
| Operational Flexibility | Limited; downtime can halt production. | High; can switch to manual operations if needed. |
| Storage and Shipping | More blanks per pallet and truck, reducing costs. | Requires more space for storage of pre-formed cases. |
| Customization | Generally fixed to specific box styles. | Modular or all-in-one units, highly customizable. |
Situational Recommendations Based on Industry Needs
| Industry | Wrap-Around Case Packers | Regular Case Packers |
| Food and Beverage | Ideal for bulk products requiring uniform packaging, enhancing shelf appearance and storage efficiency. | Best for diverse product types or quick changes in packaging needs; allows continuity in production during machine downtime. |
| Pharmaceuticals | Suitable for high-volume, standardized products needing secure, tamper-evident packaging. | Preferred for variable product sizes and quick scalability; essential for clinical trials or limited runs. |
| Cosmetics and Personal Care | Efficient for high-volume products such as soaps and lotions that benefit from aesthetically pleasing, uniform packaging. | Versatile for varying packaging styles, especially beneficial for gift sets or promotional packaging. |
| Electronics | Excellent for products that require consistent packaging formats for better protection during shipping. | Adaptable for packing diverse electronic products, from small gadgets to large devices, with varying protective needs. |
| Automotive Parts | Effective for larger production runs of uniformly sized items like filters or spark plugs; reduces material waste. | Useful for accommodating a wide range of part sizes and shapes, from small screws to large car components. |
| Household Goods | Streamlines packaging for bulk items like paper towels or cleaning supplies, ensuring product safety and stackability. | Provides the flexibility to handle assorted packaging needs, from heavy detergents to fragile light bulbs. |
| Agriculture and Seeds | Perfect for large quantities of seeds or agricultural products that require sturdy, uniform packaging for long-term storage. | Capable of handling variable packaging sizes, essential for seasonal or varying product types. |
Wrap-Around vs. Regular Case Packers – Paxiom is Here to Help
Deciding between wrap-around and regular case packers hinges on your specific production needs. Wrap-around packers are efficient and cost-effective for uniform products but offer limited flexibility during downtime. In contrast, regular case packers, while more expensive and space-consuming, provide crucial adaptability and continuity in production. Evaluate both types against your operational requirements and future growth plans to choose the best solution for your business. Unsure where to start? That’s where Paxiom comes in. Let us help you make the right choice with expert advice tailored to your unique needs.