Zray has announced that its carton forming equipment has been successfully integrated into a cooperative production line with Duracell, the world-renowned battery manufacturer. The high-speed carton forming machines are now running stable mass continuous production, packaging Duracell batteries into corrugated cartons at full production capacity with exceptional reliability and efficiency.

The partnership between Zray and Duracell represents a significant validation of Zray’s carton forming technology in a demanding industrial environment. Battery manufacturing requires precision, consistency, and uninterrupted production, making it an ideal test of carton forming equipment quality and reliability. The successful deployment confirms that Zray’s machines can meet the stringent requirements of global manufacturing leaders.

Meeting the Challenges of Battery Packaging

Battery packaging presents unique challenges for carton forming equipment. The products are heavy, dense, and uniform in size, requiring cartons that are precisely formed and consistently strong to protect the batteries during shipping and handling. Additionally, battery production lines typically run at high speeds with minimal downtime, placing extreme demands on packaging equipment reliability.

Zray worked closely with Duracell’s engineering team to customize the carton forming machines for the specific requirements of the battery production line. The machines were equipped with reinforced forming mechanisms to handle the heavier carton board required for battery packaging, as well as enhanced control systems to ensure precise forming at high production speeds.

“The Duracell project was a great opportunity for us to demonstrate what our carton forming machines can do in a really demanding application,” said Zray’s project engineer. “Battery packaging pushes equipment hard—high speeds, heavy products, long production runs. The fact that our machines are running smoothly and reliably in that environment says a lot about the quality of our engineering and manufacturing.”

The production line currently operates 24 hours a day, five days a week, with the Zray carton forming machines maintaining a consistent output of fully formed cartons ready for battery insertion. The machines have achieved uptime rates well above 99%, with jamming rates holding at less than 0.2%—even better than the already impressive 0.3% industry-leading rate that Zray recently announced.

Why Duracell Chose Zray

Duracell’s selection of Zray as its carton forming equipment supplier followed a rigorous evaluation process that included technical assessments, sample testing, and reference checks with existing Zray customers. Several key factors contributed to the decision:

First was Zray’s proven track record of reliability. The company’s carton forming machines have a well-established reputation for robust construction and dependable performance, which was critical for Duracell’s high-volume production environment.

Second was Zray’s ability to provide customized solutions. Every production line is different, and Duracell needed carton forming equipment that could be tailored to its specific product dimensions, production speed requirements, and facility layout. Zray’s engineering team worked collaboratively with Duracell to develop a solution that perfectly matched their needs.

Third was Zray’s comprehensive after-sales support. With production running around the clock, Duracell needed a supplier that could provide rapid response and reliable service. Zray’s 12-month overseas warranty, local spare parts availability, and responsive technical support team gave Duracell confidence that any issues would be resolved quickly.

Fourth was the total cost of ownership. While upfront equipment cost is always a consideration, Duracell’s evaluation focused on the full lifecycle cost, including maintenance, spare parts, energy consumption, and productivity. Zray’s machines scored well on all these metrics, offering excellent long-term value.

The Benefits of Stable Mass Continuous Production

The successful integration of Zray carton forming equipment into Duracell’s production line has delivered significant benefits, most notably the ability to maintain stable mass continuous production without packaging-related interruptions. This reliability has had a positive impact throughout the production process:

• Higher overall equipment effectiveness (OEE): With packaging no longer a bottleneck, the entire production line can run at full capacity more consistently.
• Reduced labor costs: Fewer jams and less manual intervention mean operators can focus on other tasks and fewer personnel are needed to manage the packaging line.
• Improved product quality: Consistent carton forming means every package meets Duracell’s high quality standards, reducing the risk of product damage during shipping.
• Lower maintenance costs: The robust design and high reliability of Zray’s machines mean less wear and tear and lower maintenance requirements over time.
• Scalability: As production demands grow, the Zray carton forming machines have the capacity and flexibility to scale up without major modifications.

The Duracell partnership also serves as an important reference for other potential customers in the battery industry and beyond. When a globally recognized brand like Duracell chooses and successfully implements Zray equipment, it sends a strong signal about the quality and capability of Zray’s carton forming solutions.

Future Collaboration

Both Zray and Duracell have expressed interest in exploring further collaboration opportunities. As Duracell continues to expand its production capacity and upgrade its facilities, Zray is well-positioned to provide additional carton forming equipment and packaging automation solutions. The two companies are also discussing potential joint development projects, including the exploration of new packaging formats and sustainability initiatives.

For Zray, the successful Duracell project is more than just a single customer win—it’s a testament to the company’s engineering capabilities, manufacturing quality, and commitment to customer success. As Zray continues to grow its presence in the global carton forming equipment market, partnerships with industry leaders like Duracell will play an important role in driving innovation and establishing the company as a trusted supplier to the world’s top manufacturers.

In the competitive world of industrial packaging equipment, proven performance in demanding applications is the ultimate validation. Zray’s success with Duracell demonstrates that when it comes to reliable, high-performance carton forming machines, the company can compete with the best in the world.