Production Line for Placing Doy-packs into Display Boxes
Production Line for Placing Doy-packs into Display Boxes
I. Background
1. 1 Overview
This production line is designed for the high-speed secondary packaging of Doy-packs and similar pouch products. It integrates key functional modules, including product infeed, sorting and counting, display box forming, automatic cartoning, and box sealing. The line features a compact layout and precise control, enabling fully automated flow from individual pouch discharge to finished display boxes.
In addition to Doy-packs, this solution is also suitable for packaging various small pouch products, such as candies, biscuits, snacks, and ready-to-eat foods, into display boxes. It helps enterprises enhance production capacity utilization, reduce reliance on manual labor, and ensure packaging consistency and marketability.
1.2 Objectives
- Achieve automatic product distribution of Doy-packs and load them into display boxes.
- Display boxes are formed and sealed through automated processes, including box opening, folding, and sealing.
- Each display box is fixed to hold 6 small Doy-packs, ensuring neat arrangement and excellent presentation.
- The system is synchronized with the upstream Doy-pack feeding conveyor line, ensuring an efficient production capacity of ≥200 packs/min.
- Reduce labor costs, improve packaging consistency, and support flexible adjustments and expansion of the production line.
II. Product Specifications
♦ Doy-pack: Height 130 mm× Width 80 mm× Bottom Gusset 25 mm, suitable for automatic collation and cartoning.
♦ Display Box：
- Dimensions: L 170 mm × W 200 mm × H 80 mm
- Process: Box erecting → Product loading → Box sealing
- Capacity: 6 small Doy-packs per box
♦ Cartoning Capacity: ≥200 packs/min (approx. 33 display boxes/min)
III.Solution Design
This production line employs highly integrated automation modules to achieve efficient and precise cartoning and box sealing operations for small pouch products. The line consists of the infeed conveyor unit, carton forming unit, and outfeed unit, encompassing key processes such as front-end infeed, product distribution, sorting and counting, display box erecting and forming, automatic cartoning, and box sealing.
The workstations are tightly connected via a conveyor system, ensuring a continuous flow of products from infeed to finished product output. This enables stable, high-output, high-quality automated operations, while offering excellent flexibility for product adaptation and the potential for future system expansion.
3.1 Packaging Workflow
- Front-End Infeed: The production line interfaces with the upstream conveyor system, receiving products from two different devices alternately.
- Product Distribution & Alignment: A distribution mechanism allocates products based on the line rhythm, while orientation and positioning are automatically corrected during the conveying process.
- Sorting & Counting: After alignment, the pouches are counted and grouped into sets of 6 for each display box.
- Display Box Erecting & Forming: The boxes are automatically erected, folded, and pre-formed to ensure the stability of the display box structure.
- Automatic Cartoning: A push mechanism accurately loads each group of pouches into the pre-formed display box.
- Box Sealing & Forming: Sequentially, the side flaps and the bottom flap are folded, glue is applied, and the top flap is folded to seal the box securely.
- Outfeed: The finished display boxes are conveyed out for subsequent stacking or storage.
3.2 Components
♦ Infeed & Conveying Unit
- Receives finished pouches from two upstream devices: Bossar (930 mm) and FENKO (3000 mm, with curve).
- Uses Y-shaped diverging conveyors, straight/combined/auxiliary conveyors to automatically distribute and guide products, ensuring efficient flow between workstations.
♦ Cartoning & Box Handling Unit
- Distribution Mechanism: Splits products from the two upstream outputs, maintaining balanced feed.
- Sorting & Counting Station: Sorts and positions pouches, grouping 6 packs per display box.
- Display Box Forming Station: Automatically erects, folds, and pre-forms boxes to ensure a stable box structure.
- Cartoning Station: Pushes each group of pouches accurately into pre-formed display boxes.
- Display Box Sealing Station: Sequentially folds side flaps, bottom flap, applies glue, and closes top flap to form a sturdy, well-sealed box.
♦ Outfeed Unit
- Finished display boxes are conveyed out for subsequent stacking or storage.
IV.Advantage
✅ High Automation: From product infeed, distribution, sorting, and counting to display box forming, filling, and sealing, the entire process is fully automated, requiring only minimal supervision.
✅ Flexible Adaptation: The system can be adjusted to different packing quantities or display box sizes according to customer needs, supporting multi-format product changeovers.
✅ Stable Packaging Quality: Each stage is strictly controlled to ensure that the display boxes remain solid and visually appealing.
✅ Intelligent Monitoring: A multi-level conveying and buffering design ensures continuous production, while the intelligent monitoring system detects anomalies in real-time to prevent interruptions.
✅ Scalability: Reserved interfaces allow future integration of carton packing, sealing, and coding modules to achieve complete end-of-line packaging automation.
V.Conclusion
This production line, through its highly automated design, achieves high-speed, precise, and fully automated cartoning for small pouch products. Compared to traditional manual operations, production efficiency is significantly improved, and packaging quality is more stable and consistent. The system’s flexible design allows for easy adaptation to various product specifications and carton quantities.
Additionally, the entire line is equipped with reserved expansion interfaces, supporting future integration of carton packing, sealing, and coding processes to meet customer-specific requirements and the possibility of multi-product production. With this solution, customers can reduce labor costs while enhancing line flexibility and market responsiveness, providing a solid foundation for future scale-up and multi-product production.
