Cases & Cartons

Image

Automated Case & Carton Handling Systems

Cases and cartons are central to many end-of-line automation systems — but the terms often describe different stages of the same packaging process. In many applications, the carton is open during robotic case packing. Once the product is loaded and the carton is closed, sealed, or otherwise secured, it becomes a finished case that moves downstream to palletizing, stretch wrapping, double stacking, and distribution.

Kaufman Engineered Systems designs, builds, and integrates automated systems for both stages of this process: robotic carton loading and case packing, followed by reliable case handling, palletizing, depalletizing, conveying, and load securing.

Whether the application involves loading product into open cartons, orienting products for case packing, palletizing sealed cases, or integrating the full end-of-line process, Kaufman engineers automation around the product, carton style, case format, line speed, pallet pattern, and downstream requirements.

ImageAbout Kaufman Engineered Systems

Tier-forming cell with a custom conveyor that sends the position of incoming cases and destination/orientation directions directly to the robots so they can quickly build each tier in the correct formation for the palletizer.

Using FANUC robots, KPac case packing systems, custom end-of-arm tooling, engineered conveying, pallet handling, and integrated stretch wrapping systems, Kaufman helps manufacturers move products from carton loading to finished pallet loads with greater speed, consistency, and reliability.

Videos
Contact Us
Join Our Mailing List

Requirements for Successful Automation

In a typical automated packaging process, products may be picked, oriented, grouped, and placed into an open carton. Once loaded, that carton is closed or sealed and becomes a case that continues through the end-of-line system.

That transition matters. A successful system must account for both the precision required during carton loading and the durability, stability, and flow required once the case is sealed and ready for palletizing.

Kaufman’s case and carton automation systems are designed around the product format, carton size, case style, loading method, production rate, pallet pattern, downstream equipment, and available floor space.

Common applications include:

From carton loading to finished pallet handling, Kaufman designs systems that integrate smoothly into existing production lines or new end-of-line automation projects.

The Challenges with Cases & Cartons

Case and carton automation involves more than moving boxes. During packing, the system must accurately place product into open cartons without damaging the product or disrupting the carton. After sealing, the system must move finished cases efficiently into downstream operations while maintaining product flow, pallet stability, and load integrity.

Accurate Carton Loading

Open cartons require precise handling. The robot may need to pick individual products, groups of products, bags, pouches, bottles, bundles, trays, or other formats and place them into a carton in a specific orientation or pattern.

The system must account for carton presentation, product spacing, loading sequence, product orientation, and the condition of the open carton. Poor placement can create jams, interfere with closing or sealing, damage product, or slow production.

Kaufman designs robotic case packing systems to control product movement, maintain placement accuracy, and support repeatable carton loading at production speeds.

Product Orientation & Pack Pattern Control

Many case packing applications depend on more than simply placing product into a carton. Products may need to be rotated, grouped, stacked, nested, or loaded in a specific pattern to meet packing requirements.

The automation system must coordinate product infeed, robot motion, tooling, carton position, and downstream closing or sealing. Kaufman engineers these systems around the full packing process so products are loaded consistently and cartons are ready for the next step.

Reliable Case Handling

Once cartons are closed and sealed, the finished cases must move smoothly through downstream equipment. Case spacing, orientation, transfers, accumulation, merges, diverts, palletizing infeeds, and stretch wrapper integration all affect system performance.

Kaufman integrates the conveying and handling equipment needed to move sealed cases from the packing area into palletizing, stretch wrapping, double stacking, staging, or outbound load handling.

Stable Pallet Patterns

Finished cases often need to be palletized in specific patterns to maximize load stability, cube efficiency, and transportation performance. The palletizing system must account for case dimensions, weight distribution, pallet size, stack height, label orientation, product mix, and downstream wrapping requirements.

For operations running multiple case sizes or SKUs, pattern flexibility and reliable changeover are especially important. Kaufman designs systems that support consistent placement and repeatable load formation across production demands.

Depalletizing & Product Flow

Depalletizing sealed cases requires accuracy, control, and reliable downstream flow. The system may need to remove cases from single-SKU pallets, mixed pallets, or loads where cases have shifted slightly during transport.

Robotic depalletizing can reduce manual labor, improve safety, and support more consistent product flow into production, packing, fulfillment, or redistribution processes.

Labor, Safety, and Throughput

Manual case packing, palletizing, and depalletizing can be repetitive, physically demanding, and difficult to sustain at high production rates. Even when individual products or cases are manageable, the volume, reach, lift height, pace, and repetition can create ergonomic concerns and inconsistent results across shifts.

Robotic automation helps reduce labor dependency, improve workplace safety, increase throughput, and deliver more repeatable finished loads.

Our Solutions

Kaufman Engineered Systems provides more than a robot. We engineer complete case and carton handling systems that consider how products are presented, picked, packed, conveyed, sealed, palletized, wrapped, and prepared for storage or shipment.

Our systems may include:

  • KPac robotic case packing systems
  • Product picking, placing, and orienting with KPic systems
  • Carton handling and positioning
  • Robotic palletizing and depalletizing
  • Custom end-of-arm tooling
  • Vacuum, clamp, fork, spatula, or hybrid handling tools
  • Engineered conveyor systems
  • Case infeed and accumulation systems
  • Pallet handling and load transport
  • Automated slip sheet, tier sheet, or top/bottom sheet placement
  • Stretch wrapping and load securing
  • Double stacking or load staging systems
  • Integrated controls and safety systems
  • System installation, training, service, and support

Every application is evaluated based on the product, carton format, case style, production rate, footprint, pallet pattern, throughput goals, and downstream requirements. The result is a system designed to improve efficiency, protect product quality, and support long-term production demands.

Robotic Case Packing, Palletizing, & Depalletizing

Cases and cartons may move through several automation stages before leaving the production area. A product may first be robotically loaded into an open carton. After closing or sealing, that case may be conveyed to a palletizing cell, stacked into a stable pallet load, stretch wrapped, double stacked, and moved out for storage or shipment.

Kaufman designs robotic systems around the full application, including product presentation, carton loading, tooling, robot selection, case handling, infeed layout, pallet pattern, stack height, safety requirements, and downstream wrapping or securing.

Benefits include:

ImageAbout Kaufman Engineered Systems

KPal V case palletizing system with vacuum end-of-arm tooling.

  • Accurate product placement into open cartons
  • Consistent case packing patterns
  • Smooth transition from packing to palletizing
  • Reliable finished case handling
  • Consistent pallet patterns
  • Improved finished-load stability
  • Reduced manual labor requirements
  • Increased throughput
  • Improved workplace safety
  • Reduced product handling damage
  • Better consistency across shifts
  • Flexibility for product, carton, case, pattern, or SKU changes

Custom End-of-Arm Tooling

The end-of-arm tool plays a major role in both carton loading and finished case handling. During case packing, the tool may need to pick individual products, groups of products, bags, pouches, bundles, bottles, containers, or other product formats and place them accurately into an open carton. During palletizing or depalletizing, the tool may need to handle sealed cases individually, in rows, in groups, or as part of a layer.

Kaufman designs and builds custom end-of-arm tooling in-house to match the specific requirements of each application. This allows the robot to move products and cases efficiently while maintaining placement accuracy, package integrity, and finished-load quality.

The right tooling can help accommodate:

ImageAbout Kaufman Engineered Systems
  • Open carton loading
  • Product picking and orienting
  • Single-product or multi-product picks
  • Bags, pouches, bottles, bundles, trays, or other products packed into cartons
  • Sealed corrugated cases
  • Lightweight or heavy cases
  • Retail-ready case formats
  • Multiple case sizes and pallet patterns
  • Single-pick, multi-pick, row-pick, or layer-style handling
  • Applications requiring sheet picking
  • Operations with frequent product or SKU changes

Integrated Conveying & Load Securing

A reliable case and carton automation system depends on the full movement of product through the line. Product conveyors, carton handling, case conveyors, transfers, accumulation, spacing, pallet movement, sheet placement, wrapping, and load securing all affect system performance.

Kaufman integrates the supporting equipment needed to create a complete, dependable process. This may include product infeed conveyors, carton handling systems, case conveyors, pallet conveyors, transfer systems, pallet dispensers, sheet placement equipment, stretch wrapping, dual load stackers, and other end-of-line components required to move and stabilize completed loads.

ImageAbout Kaufman Engineered Systems

For case and carton applications, proper integration helps maintain production flow from robotic packing through palletizing and final load preparation. The result is a system that reduces downtime, improves consistency, protects product, and creates pallet loads that are ready for storage or shipment.

Videos

View our Channel

Kaufman Systems: Your Automation Partner

Choosing Kaufman means working with an experienced automation partner that understands the complete end-of-line process. Our team looks beyond a single machine to evaluate how products are received, packed into cartons, conveyed as cases, palletized, wrapped, and transported through the facility.

Kaufman brings together FANUC robotic integration, custom tooling, conveyor design, controls, pallet handling, sheet placement, stretch wrapping, and load securing to build systems designed for performance, durability, and long-term reliability.

Manufacturers choose Kaufman for:

  • Decades of automation experience
  • FANUC robotic integration
  • KPac robotic case packing systems
  • Custom end-of-arm tooling designed in-house
  • Systems engineered around product-specific requirements
  • Experience with carton loading and finished case handling
  • Robotic palletizing, depalletizing, packing, and handling capabilities
  • Complete end-of-line automation capabilities
  • Durable conveyor and material handling systems
  • Improved productivity, safety, and consistency
  • Long-term service, training, and support

Whether you are loading products into open cartons, conveying finished cases, palletizing sealed cases, stretch wrapping completed loads, or integrating the full process from packing to pallet handling, Kaufman can design an automation system that improves product flow and supports your operation.

Request Quote
Contact Us
Join Our Mailing List

Product Types

Kaufman Engineered Systems designs, manufactures, and integrates solutions to handle an almost limitless range of products.