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Selecting An Automatic Cartoner

Cartoners provide packaging for a wide variety of pharmaceutical, cosmetic, and consumer products. Cartoners come in two basic configurations: Horizontal, where the product is loaded into the carton from the side and vertical, where the product is loaded from the top. These machines are usually equipped with additional features such as Lot/Date code printers, leaflet inserters, and various infeed configurations.

The process of cartoning begins when the product enters the machine and is collated into a pack pattern. The machine selects a flat case, which it opens and positions for product insertion. The carton flaps are folded and tucked, or the product moves to a sealing station where the carton is sealed using hot-melt glue.

Factors for Cartoner Selection

Proper cartoner selection depends on a number of variables, including:

  • the size of the product to be cartoned
  • the number of items to be packaged
  • the size of the carton itself
  • the required cartoning speed
  • the amount of available installation space
  • requirements for product and carton size changeover
  • integration of cartoner with other packaging machines

ESS Technologies, Inc. offers a full line of vertical and horizontal cartoners that handle carton sizes and shapes typical to the pharmaceutical, cosmetic, and consumer goods industries. As a distributor for Bergami's high quality line of horizontal and vertical cartoners, ESS Technologies project engineers have design expertise in specifying and integrating the model of cartoner that meets the requirements of most any application. This application note describes ESS, Technologies, Inc.’s line of automatic cartoners.

Industries Served Features & Benefits Cartoner Options
  • Pharmaceutical Packaging
  • Nutraceutical Packaging
  • Medical Device Packaging
  • Cosmetics
  • Personal Care Products
  • Continuous Motion Cartoners
  • Intermittent Motion Cartoners
  • All Models Meet cGMP Requirements
  • Small Foot Print
  • Balcony Design
  • Cartoning Speeds from 25 to 250 Cartons per Minute (depending on the model)
  • Changeover <15-20 Minutes
  • Leaflet/Coupon/Booklet Insertion Options
  • Embossing or Ink Coding Device
  • Code Reader and Verification
  • Automatic Infeeder with Collation and Stacking
  • Extensions for Infeed Conveyors
  • Hot-melt Closure Unit
  • Carton Rejection

Cartoner Quick Selection Guide

    AS 70 AS 120 AS 150 AS 200 AS 200C AS 200L AS 200CL AS 250 AS 350 ASV
Changeover Time 15 Minutes null graphic null graphic               null graphic
20 Minutes     null graphic null graphic null graphic null graphic null graphic null graphic null graphic  
Motion, Loading Direction Continuous, Horizontal null graphic     null graphic null graphic null graphic null graphic null graphic null graphic  
Intermittent, Horizontal null graphic null graphic null graphic              
Continuous, Vertical                   null graphic
Intermittent, Vertical                   null graphic
Cartoner Speed
(Cartoners Per Minute)		 Up to 50 cpm                   null graphic
Up to 70 cpm                   null graphic
Up to 80 cpm null graphic                  
Up to 90 cpm                   null graphic
Up to120 cpm   null graphic                
Up to140 cpm     null graphic              
Up to 50 cpm           null graphic        
Up to 170 cpm       null graphic     null graphic      
Up to 250 cpm         null graphic     null graphic    
Up to 400 cpm                 null graphic  

Typical Cartoner Product Flow

The top row shows horizontal cartoner flow, and the bottom row shows vertical cartoner flow.

Flat Cartons in Horizontal Cartoner Magazine Carton Being Erected by Horizontal Cartoner Flat Leaflet and Tube Insertion by Horizontal Cartoner Tuck Flaps Closure by Horizontal Cartoner
Flat Cartons in a Standard Magazine Cartons Being Erected Flat Leaflet and Tube Insertion Into Carton Tuck Flap Closure of Carton
Flat Cartons in a Vertical Cartoner Magazine  Cartons Being Erected by a Vertical Cartoner  Flat Leaflet and Tube Insertion by Vertical Cartoner Tuck Flaps Closure by Vertical Cartoner

AS 70 Horizontal Cartoner

Model AS 70 Horizontal Cartoner Box Dimensions
  Min Max
A 80 325
B 60 270
C 15 100

(dimensions are in mm)
Output: Max. 80 cartons per minute (varies by product)
Changeover Time: 15 minutes (all dimensions change)
Carton Storage Capacity: Typ. 500 flat
Max. Absorbed Power: 1.5 kW w/ tuck-in flaps system
3.5 kW w/ hot-melt glue system
Machine Weight: 1,200 kg

AS 120 Horizontal Cartoner

Model AS 120 Horizontal Cartoner Box Dimensions
  Min Max
A 15 120
B 15 80
C 120 200

(dimensions are in mm)
Output: 25-120 cartons per minute (varies by product)
Changeover Time: 15 minutes (all dimensions change)
Carton Storage Capacity: Typ. 500 flat
Max. Absorbed Power: 2.0 kW w/ tuck-in flaps system
3.9 kW w/ hot-melt glue system
Machine Weight: 1,150 kg

AS 150 Horizontal Cartoner

Model AS 150 Automatic Horizontal Cartoner Box Dimensions
  Min Max
A 15 120
B 10 70
C 70 200

(dimensions are in mm)
Output: 25-140 cartons per minute (varies by product)
Changeover Time: 20 minutes (all dimensions change)
Carton Storage Capacity: Typ. 500 flat
Max. Absorbed Power: 1.9 kW w/ tuck-in flaps system
3.9 kW w/ hot-melt glue system
Machine Weight: 1,150 kg

AS 200/250 Horizontal Cartoner

Model AS 200 Automatic Horizontal Cartoner Box Dimensions
    Min Max
AS 200 A
B
C		 25
15
60		 90
70
200
AS 200C A
B
C		 25
15
60		 90
70
150
AS 200L A
B
C		 25
15
60		 150
70
200
AS 200 CL A
B
C		 25
15
60		 150
70
150
AS 250 A
B
C		 25
15
60		 90
70
150

(dimensions are in mm)
Output: 35-250 cartons per minute (varies by product)
Changeover Time: 20 minutes (all dimensions change)
Carton Storage Capacity: Typ. 500 flat
Max. Absorbed Power: 3.7 kW w/ tuck-in flaps system
3.9 kW w/ hot-melt glue system
Max. Machine Weight: 2,000 kg

AS 350 Horizontal Cartoner

Model AS 350 Automatic Horizontal Cartoners Box Dimensions
  Min Max
A 25 90
B 15 50
C 60 150

(dimensions are in mm)
Output: Up to 400 cartons per minute (varies by product)
Changeover Time: 20 minutes (all dimensions change)
Carton Storage Capacity: Typ. 500 flat
Max. Absorbed Power: 4.8 kW w/ tuck-in flaps system
3.9 kW w/ hot-melt glue system
Machine Weight: 1,900 kg

ASV/ASV 50/ASV 60 Vertical Cartoners

Model ASV 60 Automatic Vertical Cartoner Box Dimensions
  ASV ASV 50 ASV 60
  Min Max Min Max Min Max
A 80 325 35 100 20 120
B 60 270 50 230 20 100
C 15 100 60 130 40 180

(dimensions are in mm)
Output: Max. 90 cartons per minute (varies by product and model)
Changeover Time: 15 minutes (all dimensions change)
Carton Storage Capacity: Typ. 500 flat
Max. Absorbed Power: 2.5 to 4.5 kW (varies by model)
Machine Weight: ASV: 1,150 kg
ASV 50: 1,000 kg
ASV 60: 2,550 kg