Modular Automation
Start where you are. Automate what matters most. Scale when you’re ready.
Automation doesn’t have to be all-or-nothing. If labor challenges, rising costs or inconsistent output are slowing your packaging line, you likely don’t need a complete system overhaul – at least not all at once. With INSITE’s modular automation, you can introduce automation into your line in manageable phases.
Start where it makes the most sense for your operation — whether that’s erecting, loading, sealing or palletizing — then expand over time. It’s a lower-risk way to reduce labor dependency and scale confidently as your production demands grow.
A Smarter, Lower-Risk Path to Packaging Automation
Modular automation allows you to increase throughput, reduce manual labor and improve consistency without committing to everything at once.
A Clear Path from Manual to Fully Automated
Every operation starts somewhere. Each automation journey is unique based on your individual needs and pain points. Here’s one example of how modular automation can evolve as your needs grow.
ERECT
LOAD
SEAL
PALLETIZE
STAGE 1: Manual
All modules done manually (5-10 cases/minute with 4 laborers)
ERECT
LOAD
SEAL
PALLETIZE
ERECT
Manual
LOAD
Manual
SEAL
Manual
PALLETIZE
Manual
STAGE 2: Light Automation
1-2 modules automated (10-15 cases/minute with 4 laborers)
ERECT
LOAD
SEAL
PALLETIZE
ERECT
Auto
(INSITE Case Erector)
LOAD
Manual
(INSITE Hand Pack Option)
SEAL
Auto
(INSITE Case Sealer)
PALLETIZE
Manual
STAGE 3: Heavy Automation
3-4 modules automated (15-30 cases/minute with 1 operator)
ERECT
LOAD
SEAL
PALLETIZE
ERECT
Auto
(INSITE Case Erector)
LOAD
Auto
(INSITE Case Loader)
SEAL
Auto
(INSITE Case Sealer)
PALLETIZE
Auto
(INSITE Case Palletizer)
STAGE 4: Full Automation
Fully automated and integrated (30-45 cases/minute with 1 operator)
ERECT
LOAD
SEAL
PALLETIZE
ERECT
Auto Erect, Auto Load and Auto Seal
(Douglas TriVex® RLi/SLi or TriVex RL/SL with integrated INSITE erector and sealer)
LOAD
SEAL
PALLETIZE
Auto
(INSITE Case Palletizer)
How Each Stage of Automation Stacks Up
Not sure what level is right for you? We help you evaluate throughput, labor availability, floor space, budget and long-term growth plans to determine the smartest starting point.
STAGE 1: Manual
Production Capacity
LOW
Floor Space Flexibility
High
Lead Time Flexibility
High
Equipment Investment
None
Labor Investment
High
STAGE 2: Light Automation
Production Capacity
Med
Floor Space Flexibility
High
Lead Time Flexibility
High
Equipment Investment
LOW
Labor Investment*
Med
*If production is not increased
STAGE 3: Heavy Automation
Production Capacity
Med-High
Floor Space Flexibility
Med
Lead Time Flexibility
Med-High
Equipment Investment
Med
Labor Investment
LOW
STAGE 4: Full Automation
Production Capacity
High
Floor Space Flexibility
Med
Lead Time Flexibility
Med
Equipment Investment
High
Labor Investment
LOW
See INSITE’s Full Line in Action
See how a full INSITE packaging line operates by following a case through each module — erecting, loading, sealing and palletizing.
INSITE’s Automated Modules
INSITE modules are engineered to function independently or integrate into a synchronized packaging line. Parameter-driven recipe management across the entire line allows operators to generate new recipes using key case and product dimensions, simplifying changeover and minimizing downtime.
INSITE Erector
Automated case erecting with quick changeovers and consistently square cases, reducing downstream issues and labor demands.
INSITE Loader
Top-load case packing automation for rigid products with compact efficiency and reliable performance.
INSITE Sealer
Automatic case sealing across a wide range of case sizes and throughput requirements.
INSITE Palletizer
Plug-and-play robotic palletizing designed for operators—not programmers—eliminating manual pallet stacking.
Need Fully Integrated Automation?
When you’re ready for a fully integrated, high-speed packaging system, INSITE connects you with Douglas — our sister company and industry leader in advanced secondary packaging automation.
Together, we provide a clear path from modular upgrades to complete line integration.
Ready to Take the Next Step?
Tell us about your production goals, and we’ll help you map the right level of automation for your operation.
