Automatic Carton Packing Machine

Our automatic carton packing machine achieves a validated speed of ≥150 cartons per minute with an OEE ≥92% in continuous pharmaceutical production. This performance is verified through 28-day validation runs measuring: Availability ≥96% (enabled by quick changeover systems), Performance ≥98% (maintaining rated speed with minimal speed loss), and Quality ≥99.5% (ensured by integrated inspection systems). The machine utilizes servo-driven technology with positioning accuracy of ±0.15mm, validated through statistical process control showing Cpk ≥1.67 for all critical parameters.

We guarantee product damage rate ≤0.003% through our precision handling system featuring servo-controlled grippers with programmable force profiles (2-40N adjustable), vibration damping technology reducing impact forces to <1.5G, and intelligent carton forming with multi-stage opening sequence. Validation using high-speed cameras (2000fps) confirms gentle product handling, while carton integrity testing per ASTM F2097 standards demonstrates seal strength ≥20N/25mm and perfect glue application.

Our recipe-based quick changeover system enables complete format transitions in ≤5 minutes using standard tools. The system employs RFID-coded tooling that automatically configures machine parameters, motorized adjustments for all critical dimensions, and auto-calibration of detection systems. Changeover precision is verified through laser measurement ensuring ±0.2mm repeatability, with validation data from 500+ change cycles showing consistent performance across pharmaceutical and food packaging applications.

Our machine accommodates diverse materials through adaptive material handling technology with specific capabilities: coated paperboard (200-400gsm), corrugated materials (E/F flute), and recyclable board (with specialized glue application). The system features automatic material recognition, intelligent glue temperature control (maintaining ±1°C), and pressure profiling that ensures perfect carton formation regardless of material characteristics, validated through 3-point board quality testing.

Our energy monitoring shows average consumption of 0.065 kWh per 100 cartons at maximum speed, achieved through: regenerative drive systems recovering ≥48% of deceleration energy, IE5 premium efficiency motors reducing base load to 16.8 kW, and smart power management automatically reducing energy during brief stoppages. The machine incorporates efficient servo drives and optimized air management cutting compressed air consumption by 50%, with ISO 50001 certification validating energy performance.

We implement comprehensive contamination control including: 316L stainless steel construction (Ra ≤0.3μm) in all product contact areas, quick-disconnect components enabling thorough cleaning, and validated CIP systems achieving 4-log bioburden reduction. Cleaning validation per EMA guidelines demonstrates residue levels <0.05 μg/cm², with comprehensive documentation supporting regulatory submissions for both pharmaceutical and food applications.

Our machine features full Industry 4.0 capability with OPC UA and PROFINET interfaces enabling seamless integration with upstream and downstream equipment. The embedded IoT platform monitors >180 parameters in real-time, while predictive maintenance algorithms analyze component performance. The system supports automatic data exchange with MES/ERP systems and provides electronic batch records with full 21 CFR Part 11 compliance for pharmaceutical applications.

We've implemented predictive maintenance technology that monitors component condition in real-time. The maintenance schedule includes: daily autonomous maintenance (8 minutes visual inspection), weekly preventive maintenance (35 minutes for lubrication and verification), and comprehensive maintenance (4 hours every 4 months). Critical components have documented service life of ≥30,000 hours, with automated maintenance alerts and guided procedures ensuring optimal machine availability and performance.

Our high-speed vision inspection system utilizes multiple 5MP cameras with LED strobe illumination capturing images at 400 frames per second. The system performs comprehensive inspection for: print quality (verifying batch codes with ≥99.99% accuracy), package completeness (detecting missing inserts or leaflets), and seal integrity (identifying defects ≥0.5mm). Advanced algorithms achieve defect detection rates ≥99.98% with false rejection rates ≤0.01%, validated using statistical process control methods.

We deliver complete validation packages including: Installation Qualification (IQ) with full component traceability, Operational Qualification (OQ) with predefined acceptance criteria, and Performance Qualification (PQ) protocols for multi-batch consistency. Our documentation follows GAMP 5 guidelines and includes risk assessment reports, traceability matrices, and cybersecurity documentation. We provide 24/7 global support with ≤2-hour response time for critical issues, backed by strategically located spare parts warehouses guaranteeing ≤18-hour delivery for essential components worldwide.