Cartoning Machines & Cartoners

Cartons are one of the most visible and important forms of packaging. They are prominent on the shelves of supermarkets and other retailers, and are a key element in FMCG (Fast Moving Consumer Goods) logistics, handling and product presentation.

Cartoners which erect, fill and seal on one machine are sometimes called Carton Form, Fill, Seal machines.

What is a Carton Packing Machine?

Cartoning machines or cartoners are packaging systems which erect, close and fill sealed cartons. In essence, they pick up a flat carton (known as a blank), erect it into a rectangular shape, push the product into the carton (or fill it through a vertical flow), and close the carton via end flaps or a fold-over lid. Machines can be semi-automatic or fully automatic.

There are multiple types of cartons including open sleeves and many different types of tuck, overlap and seal. Many use a simple fold to close, others use pre-cut tabs and slots or glue. Some cartoning machines and systems are patented (e.g. Tetra Brik) and can only be used on specific machines, while other patented designs like 'crashlock' cartons can be installed on a wide range of machinery.

Cartons also come in a wide variety of shapes including hinged lids, triangular, hexagonal, octagonal, double-wall, frame-wall, wave-shaped cartons and tapered trays.

What are cartons made of?

The key material is cartonboard, a semi-flexible paper material made up of layers of wood-based fibre. They should not be confused with Cases which are made from rigid corrugated board and are larger, often containing a number of cartons for transit. It is heavier and more robust than paper, but lighter than rigid, heavyweight board for packing and cases. For drinks cartons an impervious laminate is added. If the product is to be visible, the cartonboard can feature a pre-cut window over which a see-through laminate is applied.

What products are cartoning machines used for?

Cartoning machines are used in all fast moving consumer goods sectors but especially food, confectionery, tobacco, tea and coffee, pharmaceuticals, toiletries, cosmetics, household products and DIY.

Cartoning machines are particularly important in the non-carbonated beverages industry but it is important to recognise that while the Combibloc carton is produced on a variant of a mandrel cartoning machine the apparently similar Tetra Brik cartons are produced on special vertical form fill and seal machines.

Key considerations in deciding on which type of cartoning machine to use include budget, the materials you use (including your approach to sustainability), size of carton, throughput capacity, transport and your target market.

Find Experts in Cartoning Machines and Cartoners

You can see a list of PPMA members who can supply the know-how and machinery you need for your Cartoning Machine projects.

See also – Carton Erecting Machines

Cartoners

Horizontal End Load Cartoner

A packaging machine which erects a folded and side seam sealed carton and places it into a horizontal mechanism so that the carton can be filled horizontally by pushing the product into the carton through the open end flap prior to these being closed in the machine. Horizontal end load cartoners are the most widely used type of carton packing for products as diverse as cornflakes, toothpaste and inkjet cartridges.

Vertical Cartoner

A packaging machine which erects a folded and side seam sealed carton blank and places it into a horizontal mechanism so that the carton can be filled vertically through the top of the carton before being closed. These machines are used to fill products like porridge oats and dog biscuits.

Pre-Made Bag-In-Box Cartoner

A vertical cartoner which erects folded and side seam sealed carton blanks which contain a tube of flexible film. The base of the tube is sealed before it is filled vertically with a product. After filling the top of the tube is sealed before the carton flaps are closed. These machines are used to fill products like lawn fertilizer.

Reel Fed Bag-In-Box Cartoner

A vertical cartoner which erects a folded and side seam sealed carton blank before forming a bag from a reel of flexible film which is placed into the carton. The bag is vertically filled with product and sealed before the carton flaps are closed. These machines are used to fill cartons of instant coffee and icing sugar.

Wraparound Cartoner

A packaging machine which wraps a carton blank around a product, usually with the aid of a mandrel, before closing the carton with adhesive or tucking.

Carton Erecting Machinery

Carton Blank Erecting Machine

A packaging machine which forms carton blanks into cartons and secures them by engaging pre-cut tabs and slots, by applying adhesive or by applying heat to pre-coated cartons.

Skillet Erecting Machine

A packaging machine which erects pre-glued cartonboard skillets. The skillet erecting machine secures the flaps at one end of the carton by engaging pre-cut tabs and slots, by applying adhesive or by applying heat to pre-coated cartons.

Tray Erecting, Loading and Sealing Machine

A cartoning machine in which a cartonboard tray blank is partly formed before being loaded horizontally with a product. After loading the cartonboard tray is fully formed and sealed in the machine. This type of machine is used to form retail ready trays of products like Oxo cubes and Aspirin.

Carton Closing Machinery

End Flap Carton Closing Machine

A cartoning machine which closes cartons using the end flaps by engaging pre-cut tabs and slots, by applying adhesive or by applying heat to pre-coated cartons. Most machines of this type are semi-automatic and used to seal manually erected and filled cartons.

Three Flap Carton Closing Machine

A cartoning machine which closes cartons with only three flaps and secures them by applying adhesive or by applying heat to pre-coated cartons. Machines of this type are generally used in conjunction with a carton blank erecting machine and product is loaded into the cartons between the two machines either manually or using a pick and place loading machine.

Carton Form Fill & Seal Machinery

Mandrel Carton Form Fill Seal Machine

A packaging machine which forms cartons from either magazine fed or reel fed carton blanks around one, or a number of mandrels before filling the cartons with a product and closing them in the machine. A variant of this type of machine is used to make "Combibloc" cartons.

Mandrel Bag-In-Box Machine

A packaging machine which forms a bag from a reel of flexible material on a mandrel around which a carton blank is formed to produce a bag-in-box package. This is then filled with the product before first the bag and then the carton is closed. This type of machine is used to make the classic loose tea carton.

Top Load Carton Form Fill Seal Machine

A cartoning machine in which a carton blank is partly formed into an open top carton before being loaded vertically with a product. After loading the carton is fully formed and sealed within the machine. These machines are used to form retail ready packs of products like confectionery.

Wraparound Sleeving Machine

A packaging machine which wraps a cartonboard sleeve blank around a product or group of products and securing it by engaging pre-cut tabs and slots or with adhesive. These machines are used extensively for packing ready meals and yoghurt pots.