Endoline solves sticky box challenge for global gum giant

Providing additional strength, doubling line speed and reducing consumable tape costs, Endoline was the only automation company globally that possessed the capability to engineer a solution that met all of the criteria specified by this popular confectionery brand.

Used to seal heavy, pre-loaded chewing gum cases, the award-winning 407 High-Speed Random Case Gluer from Endoline was designed to adapt to varying cardboard case sizes entering a machine in succession. For brands supplying multiple retailers, especially confectioners, this is becoming increasingly imperative to improve production line efficiency.

This first-of-its-kind case packer can reach unparalleled speeds of 16-18 random sized cases per minute. With precision and accuracy, the 407 automatically adjusts its settings to hot glue boxes of varying heights, widths and depths, securely at the top and bottom, in whatever random sequence they are presented to the machine. For optimal flexibility, the machine can accommodate case sizes ranging from 300-560mm length, 170-350mm width and 210-360mm height.

"This increased efficiency is due to the inclusion of servo drives, rather than cam drives, which allows greater acceleration and deceleration of the moving heads and side drives during the sealing process. With the added support of sensors and barcode scanners, plus an infeed conveyor that centralises each case with guides to feed into the machine, the 407 can significantly increase a manufacturers' packing throughput and reduce labour costs, helping optimise their entire downstream supply chain operations," explains Andrew Yates Managing Director at Endoline Automation.

Making a case for sustainability

Many high-speed packaging lines require the sealing of numerous sized boxes in a row. Additionally, a growing number of manufacturers are opting for more secure, sustainable, tamper-evident sealants, namely hot glue. But what's driving this change?

"Choosing glue packaging over tape isn't just about precision; it's about trust. While glue machines may operate at a slightly slower pace, the tamper-evident seal they create offers customers an added layer of security and confidence in their product integrity," notes Andrew.

Once set, a glue seal is virtually impossible to remove. Tape can often be reapplied or stuck back down, not only increasing the risk of tampering but also the likelihood of customer complaints and returns.

For Endoline's most recent customer, the strength that glue adhesion offers was the biggest turning point. "Compared to tape, glue adhesion is much better suited to heavy cases, such as confectionery, bottles, eggs and jars. Plus, tape tends to either unstick in the heat or go brittle in the cold. Glue is a lot more durable in all weather conditions," expands Endoline Automation's Export Sales Manager, James Ramsey who oversaw the installation at the customer's Australian facility.

Like many processors, glue, rather than tape, supported the confectionery giant's net zero targets and sustainability objectives. This is due to the fact that glue is a much more environmentally-friendly option that enhances the recyclability of cardboard boxes. This in turn reduces the company's environmental impact.

Factoring in all of these different features, industry experts have reported that glue granules can be up to three times less expensive than using tape per case sealed over the long term. Moreover, glue tanks can generally be refilled while the machine is running, versus stopping a machine to reload a tape roll, leading to much higher machine uptime and more productive, cost-effective processes. The machine features a full sensor kit to pre-empt and inform an operator if glue is running low. Using HMI messaging, the machine will alert operators using visual or audible alarms.

Innovation in action

A unique and distinct feature of the confectionery company's packing process is that the cardboard boxes are selected, opened and filled manually. Three case packing lines then feed into the 407 centralised conveyor. Once the box is guided into the machine, a scanner scans a barcode on the side of the case and sends a signal to the PLC to give the machine the exact case dimensions. The machine then sets the case into position, ready for sealing.

Passing over the gluing systems, the flaps are opened just enough to apply the glue without packs of chewing gum dropping out. Glue is applied to the top and bottom flaps, allowing the box to be sealed from both ends concurrently.

The 407 High-Speed Random Case Gluer applies an indexing spacing system to carefully control and avoid multiple cases entering the gluing space at the same time. For employees health and safety, the machine features a fully interlocked guarding system to prevent injuries and stop the machine if a door is opened.

Simple to operate and maintain, the installation fit into the exact footprint of the previous legacy automated gluing machine. The Endoline system was also able to integrate seamlessly with a reduced length infeed, compact reject conveyor space, and an outfeed that directly exited onto an incline conveyor.

"One of the unique features which allowed us to engineer a solution that fit into their existing footprint was the 407's ability to automatically adjust to suit different case heights, widths and lengths. By accommodating the 'random' case sizes, the factory didn't need multiple sealers as the 407 can glue seal every box size. Further saving on investment costs, labour and operational savings," praises Cameron McKenzie, local distributor, and General Manager at Metric Engineering Solutions.

The 407's impact

"The 407 system offers remote access, meaning users can adjust the programme settings, setting the machine to operate 24/7, with minimal human intervention," explains James.

Fully-automated, robust and reliable machinery that can be programmed remotely is especially important in production environments that are operating up to 24 hours a day, 7 days a week, with very high throughput volumes.

"We estimate that these three machines installed for our confectionery client will have a rapid ROI as a result of increased efficiency, labour, and operational savings and reduced product tampering and waste," asserts James.