Introduction
At a Glance
Most common case erector problems are caused by the same 11 root problems:
- Corrugate Quality and Variability
- Storage and Environment
- Setup and Changeover Misalignment
- Air Componentry and Maintenance
- Cleaning and Environmental Wear
- Poor Tape System Sealing Quality
- Hot Glue Sealing Degradation
- Blocked Sensor Stoppages
- Case Variation in Sealing
- Out-of-Square Cases Downstream
- Jam-Clearing Safety Risks
The better you know your system, your team, and your facility, the better equipped you will be to avoid these issues – and to purchase the case erector that protects your uptime.
Have you ever wondered what causes most case erector problems? Or maybe you’re stuck with a machine that repeatedly jams, misfeeds, or produces out-of-square cases? Oftentimes, common case erector problems have causes that are easily identified, if you know where to look.
Whether your problems lie in a sensitive machine, underdeveloped processes, or improper maintenance – the better you know your case erector, the better equipped you’ll be to avoid future issues.
In this article, we’ll cover:
- The basic operations of a case erector
- Common phrases that raise red flags
- 11 root causes of most case erector problems
- 2 realistic quick guides for a smooth case erector
- Next steps to protect your uptime
How Does a Case Erector Work?
To identify how common case erector problems occur, it’s helpful to first understand the sequence of a case erector’s work. Knowing where the problems are happening can help point to a cause.
Here’s a simple, six-step, order of operations for a case erector:
1
Pick — Machine “picks” a knocked-down (KD) case from a magazine, typically using vacuum cups or pins
2
Open — Machine opens the case and breaks the fold score lines
3
Square — Machine squares the case into a rectangular tube
4
Fold — Machine folds bottom flaps
5
Secure — Machine either tapes or seals bottom flaps with adhesive
6
Discharge — Machine discharges case to downstream equipment, using sensors to prevent downstream back-ups
Automated case erectors are precise, repeatable machines. But that means even small inconsistencies – like corrugate variation, poor score depth, or a dusty environment – can result in reliability problems.
How Do I Know When My Case Erector Is Causing Problems?
If you’re looking for a quick-reference list, here are some common maintenance or operations comments, that (when heard) should set off alarms in your head:
- “It keeps jamming in the tape section.”
- “It’s failing or double picking.”
- “Boxes aren’t coming out square.”
- “Flaps aren’t folding right.”
- “Tape keeps breaking.”
- “It keeps stopping for no reason.”
If you’re hearing any of these, take a look at your case erector. Each one points to potential failure modes, and the sooner you identify the failure, the sooner you’re operating at top performance.
What Causes Case Erector Problems? The 11 Root Causes
An erector failing to pick cases could be happening because of corrugate variability, setup errors, failing air componentry, or something else entirely. The point is, a common issue like failed picks, usually has a typical cause and a straightforward solution.
Here are 11 common causes for case erector failures (plus, how to identify and avoid them):
1. Corrugate Quality and Variability
Corrugate is the single biggest source of recurring case erector problems – and oftentimes, it comes from the supplier’s side. Issues in this area appear in several ways:
Failure
Typical Source
Cases don’t open
→
Over-glued seams effectively glue the case blank shut
Cases fold oddly
→
Scores are too shallow and cases end up out-of-square
Cases form with gaps
→
Manufacturer’s joint is crooked and cases end up out-of-square
Machine picks are unstable
→
Warped corrugate or highly recycled material causes instability and tape failures
To Avoid: Test your most variable case blanks at factory acceptance testing (FAT) and site acceptance testing (SAT). Include warped, highly recycled, humidity-exposed cases, not just perfect ones.
Not Sure What to Expect from Your Corrugate?
You might consider the purchase of a Fibre Box Handbook from the Fibre Box Association. This handbook provides guidance for all sorts of corrugate, so you know what to expect from your cases and supplier.
Also take a look at our article, “What Is Corrugated Board? Flute Profiles, ECT, and Why They Affect Case Performance”.
2. Storage and Environment
Improper storage or especially humid conditions commonly cause corrugate problems. These problems often show up through reliability issues:
Failure
Typical Source
Warping, delamination, softening or increased friction
→
High humidity
Brittle, or cracking
→
Overly dry conditions
For best-bet storage and environmental conditions, follow these guidelines:
- When storing, keep the cases flat and off the floor, avoiding doorways and damp areas. For best practice, also follow “first in, first out” (FIFO) method.
- For environmental conditions, aim for 30-70% relative humidity (RH), and 40-100º Fahrenheit. These recommendations are made by the Association for Packaging and Processing Technologies (PMMI) and the Fibre Box Association.
To Avoid: If your plant experiences seasonal humidity changes, keep a record of temperature and relative humidity. Specify those conditions when talking to vendors to make sure your facility is within machine tolerance.
3. Setup and Changeover Misalignment
When automation is set up or changed over incorrectly, it naturally creates case erecting problems. Issues in this area are relatively common and can be easily remedied.
Poor setup is the biggest cause of case erector jams, especially in the following areas:
Failure
Typical Source
Case friction and jamming
→
Belts that are too close
Failed case picks and dropping
→
Misaligned vacuum cups
Cases stick and tear or tape free-spools
→
Incorrect tape head tension
To Avoid: Target buying machines that are simple and have repeatable changeovers. Look for key phrases like tool-less changeover, pictorial guides, and training support.
4. Air Componentry and Maintenance
Vacuum cups are one of the most commonly shipped wear parts. That tells us something: that air componentry is a frequent cause of problems, and it regularly requires maintenance.
Failure
Typical Source
Failed, dropped, or double picks
→
Worn vacuum cups, cracked tubing, or poorly fitting connections
Weak vacuum performance
→
Dirty filters or moisture in air lines
To Avoid: When purchasing equipment, look for the following details in your specs:
- Required air pressure and flow
- Location of maintenance access points
- Features that detect vacuum faults
These are not make-or-break buying specs, but when they’re included, they’ll make a big difference.
5. Cleaning and Environmental Wear
Without proper cleaning and preventive maintenance (PM), all machines will degrade. To identify problems caused by these wear conditions, look for the following:
Failure
Typical Source
Clogged filters, dust build-up
→
Corrugate dust accumulation
Tape and glue failures
→
Adhesive build-up on blades and rollers
Jamming and inconsistent sealing
→
Belt wear
To Avoid: When purchasing, look for equipment with a lower part count, accessible cleaning points, and wear parts. These kits will include the most commonly replaced parts (e.g. suction cups, blades, belts, etc.).
6. Poor Tape Sealing System Quality
Tape-sealing case erectors have a unique set of problems and causes. The most common tape issues like breakage, offset, and failed cutoffs, are often caused by one of the following:
- Dirty or worn tape heads
- Poor tape material quality
- Incorrect tension or threading settings
- Recycled corrugate that’s out of tolerance
To Avoid: Look for equipment with:
- Industry-trusted tape head models
- Clear adhesive monitoring and alerts
- Settings that adapt to recycled corrugate specs
Also, look for high-quality tape materials, and prefer reputable suppliers.
7. Hot Glue Sealing Degradation
Case erectors that operate with hot-melt glue tend to see the following common problems:
- Char or blockage in the nozzles
- Inconsistent glue-bead application
- Adhesive degradation
These problems can be caused by multiple issues. Some of them are process and operational, some are materials and supplier-based issues. For more information, take a look at our article, “What’s Driving My Consumables Costs? Common Gaps, Quick Fixes, and Best Practices”.
To Avoid: Treat the adhesive system like a standalone asset. Invest in quality systems with monitoring, adhesive filtration, and melt-on-demand materials.
8. Blocked Sensor Stoppages
When case erectors experience stopping, some lines immediately jump to a broken machine. However, it’s common that something has simply backed up or blocked a sensor.
Failure
Typical Source
Machine halts
→
Blocked exit sensor causes attempt to prevent back-up
Stops forming
→
Downstream pauses triggers stoppage due to lack of accumulation buffer
False faults
→
Poor sensor alignment
To Avoid: When purchasing equipment, consider it as a part of your whole line. How it will complete handoffs, what its accumulation settings will be, etc. Consider overall equipment effectiveness (OEE) for your line altogether.
9. Case Variation in Sealing
With case erectors, case height or width variation in sealing is one of the most frequently cited sources of jams.
Here are some notes:
- Even slight case width variation can affect the control between belts
- Some equipment tolerates cases better with lugged belts, or spring-loaded side belts – which can assist in case squaring
To Avoid: When evaluating with vendors, ask the question: “How does your machine handle warped, overly wide or narrow cases, when operating at full speed?”
10. Out-of-Square Cases Downstream
If your case erector sends out-of-square cases down the line, you may see packing and palletizing problems like:
- Stacking failures
- Inconsistent loads
- Unstable pallets
These issues can damage your products and your brand. Well-squared cases make for stronger stacks and more-appealing shelf presentations.
To Avoid: Pay attention to how equipment at the FAT and SAT levels handles case variation. Make sure to define with your vendor what squareness your case erector should tolerate.
11. Jam-Clearing Safety Risks
The way your case erector handles faults is likely more important than you realize. Fault clearing can pose serious risks for your team. Here are some general standards when considering machine safety:
- The more handoffs your line has, the more opportunities for pinch hazards
- Poor safety guarding leads to increased risk during troubleshooting
- More componentry means more machine complexity and longer troubleshooting
As a compliance note: lockout/tagout (LOTO) rules still apply, when unjamming the machine exposes workers to hazardous energy.
To Avoid: Safety should never be an afterthought. Consider guarding, interlocks, and safe accessibility as a factor in the total cost of ownership (TCO), rather than as just a purchase price burden.
How Do I Identify and Avoid Case Erector Problems? Two Realistic Quick-Guides
Putting good habits into practice is easier said than done. We’ve designed a guide that you can use to quickly check for problems on your machine, and another one to avoid purchasing a temperamental machine in the first place.
1. Quick-Check for Case Erector Issues
When problems are occurring at 2 am, your team wants answers fast. Here are seven quick-checks your team can do to troubleshoot for common issues:
- Check machine air pressure and clean pneumatic filter
- Inspect vacuum cups and hoses for wear
- Clean vacuum filters
- Check for proper belt spacing, and inspect belt wear
- Clean and inspect tape-head blades and rollers
- Inspect hot-melt nozzles for charring
- Check sensors are clear and aligned, and verify the discharge path
You can’t identify every case erector problem through a quick check, but these seven steps will help you verify that your core, internal equipment isn’t driving failures.
2. What to Look for in a Case Erector
The best way to avoid case erector downtime, is to buy smarter in the first place. That means knowing your line and facility, and checking that your new erector is the right fit.
Here are four insights to guide your purchase, and to check erector capabilities:
Consider Machine Specs for Your Reality
These aren’t the specs that will be in the brochure, but they’re worth verifying with your vendor:
-
Corrugate Types – Can the erector run my corrugate types?
Include details like percentage of recycled material, and style and depth of scoring
-
Environment – Will the erector excel in my environment?
Know your yearly humidity range and any facility conditioning practices
-
Line Integration – Will the erector fit within my whole line?
Know the details of your line’s other equipment
Advocate for FAT and SAT to Include Quality Checks
A good vendor will make the FAT and SAT suit your needs. Make sure to include the following:
- Vendor inspection and evaluation of consumables (especially corrugate)
- Test jam rates with worst and most variable case blanks
- Test what out-of-square cases the erector will tolerate
- Test quality of machine seals (e.g. tape centering or glue consistency)
Consider Machine Systems that Reduce Failure Risk
Whether you use these systems as a qualification for your scope, or just ask about them as optional add-ons – these technologies are worth considering:
- Positive-Force Opening – Uses vacuum cups to hold open the case, rather than grabbing by the edges; more reliable overall
- Active Case Squaring – Senses how square a case is, adjusting belt speeds to ensure squareness through sealing
- Spring-Loaded or Adaptable Belt Systems – Allows for variation and more flexibility in case width
- Open Machine Design – Clear and accessible design, without frame obscuring reach
- Adhesive System Monitoring – Provides feedback on sealing system status and flags faults when issues arise
Scope for Speed Headroom
Since vendor-rated speeds can be misleading, it’s best to buy an erector that’s 10-15% over your rated line speed. That should give you enough headroom to protect your uptime.
Additional headroom also allows your erector to pause if needed (e.g. magazine loading, tape roll change), while also being able to catch up.
What Are My Next Steps? Valuing the Case Erector’s Place in Uptime
It’s a mistake to underestimate your case erector – it sits at the top of your secondary packaging line, and everything downstream is affected by its performance. Buy a good case erector that will protect your uptime, and keep it properly maintained to prevent premature wear.
Whether you’re looking to purchase a new case erector or to improve your current one, your next step is to define what your facility, line, and erector need to succeed. Once that happens, effective performance and line growth should follow.
Interested in Learning More About Case Erectors?
Take a look at some of INSITE’s other case erector-focused articles:
Are You Interested in Exploring a New Case Erector?
Give INSITE a call. Our specialists will simplify the buying process by answering questions, highlighting options, and evaluating the right fit within your line.
