In the world of industrial packaging, every stage of the process must be smooth, precise, and reliable. One of the key elements in many lines is the case former: a machine whose task is to transform cardboard boxes that are still flat (or partially folded) into their final “open” shape, ready for filling and subsequent sealing.
What case formers do
- Opening / forming: starting from a folded (or flat-stacked) box, the case former opens the side and bottom flaps so that the box takes on the correct shape, with well-squared edges.
- Support / hold of the bottom flaps: it keeps the bottom flaps open and stable while the operator (or a downstream automatic system) inserts the contents.
- Preparation for closing: it is often combined with – or positioned in line with – a case sealer which, once the box has been filled, applies adhesive tape to seal the bottom.
- Synergy with the case sealer: the case former is commonly installed upstream of the case sealer; after the box is formed and kept stable, the operator (or automation) fills it, and the case sealer finishes the process by applying the tape.
This workflow (forming → filling → sealing) makes it possible to optimize time, reduce manual intervention, improve reliability, and minimize errors (poorly formed boxes, bent flaps, imperfect sealing).
Why use a case former (instead of forming each box manually)
- Speed: automatic or semi-automatic machines are much faster than manual forming, especially for medium or large batches.
- Consistency and precision: every box is formed with the same angle and the same pressure on the folds, reducing defects.
- Reduction of operator error: fewer manual operations also mean a lower risk of incorrect folds or accidental damage.
- Line scalability: in facilities where volume increases, automation makes it possible to absorb production growth without proportionally increasing staff.
- Integration into existing lines: many case formers are designed to be easily inserted upstream of case sealers or closing stations, minimizing changes to the system.
Types: semi-automatic vs automatic
Semi-automatic case formers
In semi-automatic models, the operator manually inserts the box into the case former. The machine then performs the automatic operations (opening, folding, holding). Some key points:
- They require an operator to feed/position the boxes.
- Moderate speed (some models reach 5–12 boxes per minute, depending on the size).
- Ideal for mixed production or varying formats, where flexibility is important.
- Lower investment cost compared to automatic models.
Automatic case formers
In automatic models, the entire process—box pickup, opening, folding, transport to the filling station, and even integration with tape sealing—is managed automatically, without human intervention (or with minimal intervention). The main features are:
- Very high speeds (some models reach 840 pieces per hour or more).
- Format change (box size) adjustable via control panel, handwheels, or in advanced versions, through automation.
- High flexibility when working with uniform stock.
- Compact design for integration into existing lines, even in limited spaces.
- Capability for synchronization with sensors, photocells, automatic start/stop, downstream conveyors, etc.
These automatic models allow for handling large volumes consistently and integrating easily into the automated packaging line.
When selecting a case former (semi-automatic or automatic), attention should be paid to the following parameters:
| Parameter | Why it is important | Typical values / notes |
| Box size (L × W × H) | The machine must be able to accommodate the maximum and minimum box sizes of the batch. | For example, F1000: max 400×400×500 mm |
| Productivity | How many pieces per hour or per minute the machine can handle | 840 boxes/hour for the F1000 |
| Carton magazine (capacity) | Number of folded boxes that can be loaded into the feeder (for automatic models) | F1000: approximately 110–120 standard boxes |
| Power supply and electrical requirements | To check compatibility with the company’s electrical system | F1000: three-phase 400 V power supply, installed power ≈ 1.5 kW |
| Compressed air / pneumatic consumption | Many movements (suction cups, pistons) are pneumatic. | F1000: 6 bar, 13 Nl per cycle |
| Integration with case sealers / line | It must “communicate” with the sealing / filling station. | Some models include automatic Start/Stop via photocell. |
| Structure and materials | In harsh environments, stainless steel and durable finishes are preferable. | Stainless steel versions available in some F1000 models. |
In addition to these, useful options include motorized feeders, models with conveyors, touch screen control systems, cardboard integrity sensors, and empty-box prevention devices.
Models and features
PACK POINT 08
| MODEL | PACK POINT 08 |
| Box size | Length (L) from 180 to 650 mm. Width (W) from 140 to 500 mm. Height (H) from 100 to 500 mm |
| Maximum production rate | 300 boxes/h |
| Temperature of use | from + 5°C to + 35°C |
| Machine plan dimensions | Length (L) 1240mm, Width (W) 805mm. |
| Machine height | mm. 870 |
| Weight | 125 kg |
| Compressed air supply | 5 bar |
| Work surface height | 650 mm |
| Consumption per cycle | 7,5 nl |
F1000 AUTOMATIC CASE FORMER
| MODEL | CARTON ERECTOR F1000 | ||
| Size cartons to form | Lenght | Width | Height |
| minimum mm. 180 | minimum mm. 100 | minimum mm. 100 | |
| maximum mm. 400 | maximum mm. 400 | maximum mm. 500 | |
| Productivity max | 840 pieces/hour | ||
| Box transfer speed | about 22 mt/min | ||
| Operating temperature | from +5°C up to +35°C | ||
| Dimensions of the carton former including the taping base | mm. 1100x1850x1800h | ||
| Weight | Kg. 490 | ||
| Compressed air supply | 6 Bar, 13 Nl per cycle | ||
| Working plan height | mm. 650 + 30 | ||
| Charger capacity | 110/120 boxes | ||
| Power supply | three-phase, 400V | ||
| Installed power | 1,5 Kw | ||
| Venturi vacuum system | 25m3/h 700 mm HG | ||
| Electrical protection | IP 54 | ||
| Maximum noise | 78 db | ||
F2000 AUTOMATIC CASE FORMER
| MODEL | ERECTOR F2000 | ||
| Formig boxes size | Lenght | Width | Height |
| minimum mm. 220 (200 mm. on demand) | minimum mm. 100 | minimum mm. 100 | |
| maximum mm. 600 | maximum mm. 500 | maximum mm. 500 | |
| Productivity max | 840 pieces/hour | ||
| Operating temperature | from +5°C up to +35°C | ||
| Dimensions of the carton former including the taping base | mm. 2435x2110x1800 | ||
| Weight | Kg. 490 | ||
| Compressed air supply | 6 Bar, 13 Nl per cycle | ||
| Working plan height | mm. 650 + 30 | ||
| Charger capacity | 110/120 boxes | ||
| Power supply | three-phase, 400V – 50 Hz – 1 Kw | ||
| Electrical protection | IP 54 | ||
| Maximum noise | 78 db | ||
Conclusion
Case formers, both semi-automatic and automatic, represent a strategic component in modern packaging lines. They allow:
- speeding up the box preparation process,
- standardizing the quality of box forming,
- reducing errors and manual interventions,
- easily integrating with case sealers and filling stations.
The choice between a semi-automatic or automatic model depends on factors such as production volume, frequency of format changes, available budget, and the configuration of the existing line. It is essential to carefully evaluate the technical parameters (size, productivity, pneumatic consumption, integration) and review illustrations, datasheets, and production references (such as the F1000 / F2000 range offered by Ferplast).
For more information, or for a personalized free quote, we invite you to contact us by sending an email to info@sos-imballaggio.com OR by calling 01732123.
