Material Handling System for transport and storing cardboard boxes to the packaging area
Transport and storage of boxes
We present a fully automated system for managing the flow of cardboard boxes between automatic box formers and packaging lines. We have implemented an automated transport system, identification according to the barcode specific to each type of box, and distribution of cardboard boxes directly to the packaging lines.
Fast and accurate box ordering
Workstation distribution is done automatically according to production software on each line or requests made by operators on a display located in the workstation area. In this project, we focused on making the flow of boxes between the forming chamber and the packaging area as clear and easy to manage as possible. Operators can order the required types and volumes from a touch screen HMI terminal, and orders are automatically transmitted to the automatic box forming area. This eliminates confusion and loss of information between teams.
The boxes are transported on a narrow conveyor belt, on their sides, which has allowed us to use very little space without affecting transport stability. Barcodes applied on two sides help with accurate identification: the scanner recognizes the type of box and automatically directs it to the station that requested it.
For situations where the box reaches the operator's area but is not picked up immediately, we have provided an accumulation loop. Here, the boxes can circulate until the operator is available — a simple solution that avoids bottlenecks and keeps the flow constant.
Overall, the system brings order, predictability, and a much smoother flow between the two production areas. Operators receive the correct boxes on time, and manual handling and errors are significantly reduced.
Automation of box feeding in the product packaging area:
🔧 Key features:
✅ Narrow conveyor transport (200 mm), with edge movement for maximum efficiency.
✅ Barcodes marked on two sides of the box for identification in the flow.
✅ Scanner for recognizing the type of box and directing it to the operators who generated the order.
✅ Accumulation loop for uncollected items, with automatic return to the control area.
✅ Automatic vertical or lateral diverters, electric, pneumatic, or hybrid.
This system optimizes the flow between the cardboard box forming and packaging areas, eliminating the manual transport of stacks of boxes by operators with pallet trucks in the production area aisles.
Benefits:
➡️ Increases productivity and eliminates the movement of boxes and crates along production lines.
➡️ Clear flow of orders for boxes needed in production and automatic box forming area, according to pre-orders and planned production.
➡️ Predominantly aerial installation, small footprint on the ground.
➡️ Creates buffers in the queue for system operators.
➡️ Reduces manual handling and increases feeding speed.
➡️ Increased efficiency and reduced physical effort.
➡️ Clear statistics on boxes ordered, delivered, and times for each area of the flow.
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