Case Packers 101: Case Styles, Packaging Machinery & Value Adds

Introduction

In the world of packaging automation, understanding case styles is crucial for selecting the right case packing solution to meet your production needs. As experts in integrated packaging solutions, we are frequently asked about various case types and how they impact automation choices. This comprehensive guide will walk you through everything you need to know about common case styles and the packing technologies designed to handle them, including:

• Common Case Types in Packaging
• Automated Case Packing Technologies
• Value-Add Solution for Case Packing Equipment

Common Case Types in Packaging

Understanding the various case styles available is the first step in optimizing your packaging process. Let's examine the most common case types employed across various industries and their distinctive characteristics that make them suitable for different products and applications.

RSC/Knock-Down Cases

The Regular Slotted Container (RSC), also known as a knock-down case, is the most widely used case style across global supply chains. These versatile containers feature:

• Four side panels with flaps on both top and bottom
• A manufacturer's flap that's pre-glued during production
• Minimal material usage while fully protecting contents
• Easy manual erection from a folded state

RSCs are popular for their cost-effectiveness and versatility across nearly all product categories, from food and beverage to consumer goods.

Tray-Style Cases

Tray cases resemble RSCs but lack one side panel and two flaps. Their distinctive features include:

• Open top design that allows product visibility
• Typically uniform flap length from score to edge
• Often overwrapped after loading to create retail-ready packaging
• Reduced corrugate usage compared to full RSCs

Trays are increasingly popular for retail environments where easy shelf stocking and product visibility are priorities.

HSC (Half-Slotted Container)

The Half-Slotted Container includes:

• Similar construction to RSCs, but with only one set of flaps
• Pre-secured manufacturer's flap
• Often requires additional overwrapping or a lid
• Ideal for co-packers and repackaging operations

Wrap Around Cases

Wraparound cases are the second most common case style and offer several advantages:

• Similar final appearance to RSCs but without a pre-sealed manufacturer's flap
• Cost savings in manufacturing (no flap sealing process required)
• Space efficiency in transport and magazine loading (shipped as flat blanks)
• Better ability to conform tightly around products
• Reduced catch points compared to RSCs

Automated Case Packing Technologies

Once you've selected the appropriate case style, the next consideration is which automation technology will best suit your production needs. These advanced packing systems offer various approaches to case loading, each with specific advantages that depend on your product characteristics and production requirements.

Side Load Case Packers

Side load (or horizontal load) case packers insert products horizontally into the case. These systems:

• Can handle all common case styles mentioned above
• May require tilting some case types before loading
• Excel at efficiently packing products that can be pushed or swept into cases
• Work well with products that can withstand side pressure
• Offer some of the most advanced, flexible options for end-of-line packaging

Nigrelli's side load case packers are designed for quiet, low-maintenance operation while maximizing efficiency.

Top Load Case Packers

Top load case packers typically utilize a gantry system with specialized end-of-arm tooling to:

• Pick products from a conveyor or staging area
• Place items into cases from above
• Handle products that cannot be loaded from the side
• Accommodate RSC, tray, and HSC case styles
• Provide gentle handling for fragile items

Our top load case packers feature customizable load patterns and versatile designs for both flexible and rigid products.

Robotic Case Packing

A specialized form of top loading, robotic case packing employs:

• Six-axis robotic arms, delta robots, or SCARA robots
• Vision systems for increased flexibility
• Advanced product manipulation capabilities
• Adaptability for various case styles and product types
• Greater flexibility in pack patterns and product arrangements

With over 900 robotic systems installed across 13+ countries, BW Integrated Systems is a global leader in robotic case packing solutions.

Wrap Around Case Packers

These specialized machines:

• Form cases around products rather than inserting products into cases
• Reduce material costs
• Allow for tighter case fits
• Handle a variety of products including cans, cartons, and bottles
• Provide superior performance with low operational costs

Our wraparound packers deliver consistent performance with simple maintenance requirements.

Selecting the Right Case Packing Solution

When choosing a case packing system, consider these key factors:

• Product characteristics - fragility, shape, weight, and orientation requirements
• Production speeds needed to meet output targets
• Available floor space and line configuration
• Initial budget, expected OEE, and lifetime cost
• Cost of raw material – cases (KD vs wrap around), glue, cartons, film, etc.
• Case style preferences based on downstream handling
• Changeover frequency between products or case sizes
• Labor availability for machine operation and maintenance

View Nigrelli's case packer portfolio for examples of various styles of case packing machinery.

Value-Add Solutions for Case Packing Equipment

Beyond the machinery itself, comprehensive support and integration capabilities are crucial factors in maximizing the long-term success of your packaging line. BW Integrated Systems provides value-added solutions that enhance equipment performance, reduce downtime, and ensure your packaging operation remains efficient throughout its entire lifecycle.

Integrated Packaging Solutions

While understanding individual case packers is important, the greatest efficiency gains often come from properly integrated packaging lines. As both machine manufacturers and systems integrators, BW Integrated Systems uniquely understands how to:

• Design optimal case packing lines for your specific facility layout
• Get you a true turnkey solution for your packaging needs
• Ensure proper spacing and product flow between equipment
• Coordinate controls for seamless operation across the entire packaging line
• Maximize throughput while minimizing footprint
• Collect and share your production data and metrics to allow fine-tuning of your production line
• Create solutions that accommodate future production needs

Our comprehensive approach ensures that your case packing equipment operates as part of a cohesive system rather than an isolated component. View our Integrated Packaging Solutions webpage to learn more!

Lifetime After-Sales Support

In today's manufacturing environment, equipment reliability and consistent operation are critical to maintaining production schedules and meeting market demands. Comprehensive after-sales support provides manufacturers with ongoing technical expertise, rapid response to maintenance needs, and solutions for skill gaps caused by workforce turnover.

The most effective packaging partners offer long-term support that includes technical troubleshooting, drawings, and manuals, rapid replacement parts availability, automation upgrades to extend equipment life, and training resources for new operators. This sustained partnership approach ensures that initial equipment investments continue to deliver value throughout their operational lifespan, even as production requirements and personnel change over time. We are always here.