ZRAY Launches Heavy-Duty Master Carton Erector ZR-22HD (18–22 CPM, 30 kg Load, 11 mm Board) for Hardware and Auto Parts | ZRAY
Hardware fittings and automotive parts do not ship in light retail cartons. A master carton holding brackets, fasteners or brake components can weigh 20–30 kg, use 5-layer BC board up to 11 mm thick, and still need a square, stackable case at 18–22 cartons per minute. Standard erectors buckle here: vacuum cups tear on sharp metal edges, the forming platen deflects under box weight, and flap compression drops below what a pallet stack demands. ZRAY’s new ZR-22HD is built for this punishment class.
Why Hardware and Auto-Parts Lines Fail
Three modes dominate. Sharp stamped edges gouge cups and slice tape, causing AL-03 pickup misses. A 30 kg blank resists vacuum lift and collapses mid-form, triggering AL-04 jams. And master cartons must hold 8–10 high on a pallet, so flap closure and board ECT cannot be sloppy.
ZR-22HD Heavy-Duty Specifications
| Parameter | ZR-22HD |
|---|---|
| Speed | 18–22 cartons/min |
| Board | 5-layer BC / EB |
| Thickness | up to 11 mm |
| Load | 20–30 kg per carton |
| Sealing | dual tape head, 75 mm |
| Frame | 3.0 mm reinforced steel |
| Power | 3.0 kW, 380 V/50 Hz 3-ph (220 V/60 Hz opt) |
| Air | 0.5–0.6 MPa, ~150 NL/min |
| Control | Mitsubishi FX5U + 7″ HMI |
Reinforced Design
The 3.0 mm reinforced frame and thickened forming plate resist deflection under load. A dual suction-cup group shares lift across the blank, wear-resistant PU cups survive metal-edge contact, and an anti-metal-chip scratch coating protects machine and carton. Dual 75 mm tape heads secure heavy flaps in one pass.
Corrugated Board Range
| Board | Flute | Layers | Thickness | Weight |
|---|---|---|---|---|
| Single wall | B, C, E | 3 | 3.0–5.0 mm | 350–700 gsm |
| Double wall | BC, EB | 5 | 6.0–9.0 mm | 700–1,000 gsm |
| Heavy pre-creased | BC | 5 | up to 11 mm | 1,000+ gsm |
Flute runs vertically. For ZR-22HD the 11 mm board is run with the pre-creasing unit engaged; flute must be BC or EB for the rated 20–30 kg load.
Stacking Compression and ECT
Master cartons for auto parts need an Edge Crush Test (ECT) of 7–9 kN/m on 5-layer BC board to survive a 1,000+ kg pallet stack. The ZR-22HD closes flaps at 15–20 N compression roller pressure so the case keeps its declared ECT rather than crushing lower tiers.
Heavy-Duty PLC Alarm Codes
| Code | Description | Cause | Action |
|---|---|---|---|
| AL-03 | Pickup miss (weight) | 30 kg > single-cup lift | Engage dual-cup mode |
| AL-04 | Forming jam | Weight deflects platen | Clear, verify platen |
| AL-06 | Flap not closed | Low compression | Raise spring to 15–20 N |
| AL-05 | Tape head fault | 75 mm run-out, dull blade | Reload, replace blade |
| AL-09 | Air pressure low | <0.4 MPa | Check FRL, drain |
Preventive Maintenance Schedule
| Interval | Tasks |
|---|---|
| Daily | Drain FRL; verify 0.5–0.6 MPa; inspect PU cups; check 75 mm tape |
| Weekly | Lube guides; belt tension; clean sensors; verify dual-cup balance |
| Monthly | Vacuum filter; inspect forming plate; torque bolts |
| Quarterly | Replace PU cups; grease gearbox; verify I/O; check coating |
| Annually | Gearbox oil; insulation test; re-level; recalibrate compression |
Pair With Three-Piece Lines
For mixed master and sub-carton formats, the Three-Piece Case Erector handles lighter 3-piece styles while the ZR-22HD owns the heavy master carton. See the full product range to match both tiers on one floor.
Get a Quotation for Your Packaging Line
Send us your carton size range, board grade and required CPM — our engineers will return a model recommendation, layout drawing and quotation within 24 hours.
Contact ZRAY: [email protected] · WhatsApp +86 13681839278
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