ZRAY Introduces Turnkey Packaging Line Integrating Automatic Case Erectors and Loaders (Up to 40 CPM, OEE ≥85%) | ZRAY
Most packaging lines fail not at the machine, but at the seams between machines: a 40 CPM erector starves a 30 CPM loader, or a palletiser backs up and chokes the sealer. ZRAY’s new turnkey packaging line closes those seams by engineering the whole cell — automatic case erector, carton loader, sealer, labelling, checkweighing and palletiser — as one controlled system rated at up to 40 CPM with a line OEE target of ≥85%. One supplier, one FAT, one warranty, one service number.
Line Composition and Beat Matching
Every station is sized with a 10–15% speed margin over the bottleneck so a single slow head never stops the cell. Buffers sit between married stations to absorb micro-stops.
| Station | Speed | Buffer / note |
|---|---|---|
| Case erector (ZR-40H) | 40 CPM | Magazine 5–8 min stock |
| Carton loader / unloader | 42 CPM | Infreed accumulator 6 cases |
| Case sealer | 40 CPM | Hot-melt or tape |
| Label / inkjet coder | 45 CPM | Bypass on fault |
| Checkweigher | 50 CPM | Reject lane |
| Palletiser | 40 CPM | Slip-sheet, 1.2 t/h |
On a 40 CPM main line the loader and coder are specified 5–10 CPM above the erector, and the checkweigher runs faster still so rejects never stall the flow.
Line Control Architecture
A master line-control PLC owns the sequence; a 7″ overview HMI and optional SCADA show live CPM, alarms and OEE. Stations talk over Modbus TCP / PROFINET, the line auto-de-rates when any station becomes the bottleneck, and jam detection at each transfer drops the upstream feed. The E-stop chain is series-wired across the whole cell, so one pull stops everything in the defined zone.
Capacity and Efficiency Targets
| Metric | Target |
|---|---|
| Line OEE | ≥ 85% |
| Speed margin per station | 10–15% over bottleneck |
| Bottleneck auto-de-rate | Yes, real-time |
| Mean micro-stop recovery | < 30 s with auto de-jam |
A 10–15% margin is the difference between a line that hits nameplate and one that loses two shifts a week to cascade stops. The erector’s restart-capable PLC logic restores the full sequence after a jam without manual reset.
Project Flow
| Step | Deliverable |
|---|---|
| 1. Requirement study | Carton range, CPM, layout constraints |
| 2. Concept & layout | 2D/3D plant drawing |
| 3. Quotation & contract | Fixed scope, lead time |
| 4. Design confirmation | Sign-off drawings |
| 5. Build & FAT | Factory acceptance test |
| 6. Shipment | Crated, incoterms agreed |
| 7. Install & SAT | On-site commissioning |
| 8. Training | Operator + maintenance |
| 9. Acceptance | Handover & warranty start |
Turnkey Scope
The package covers equipment, electrical, pneumatic and conveyor integration, a critical spares kit, full documentation, on-site installation and commissioning (шеф-монтаж и пусконаладка), operator and maintenance training, and a 24-month warranty. One interface means no finger-pointing between the erector and the palletiser.
Common Pitfalls We Pre-Engineer
| Pitfall | ZRAY action |
|---|---|
| Carton tolerance drift | Infeed gauge set to board + 0.5 mm |
| Low ceiling / no crane | Modular split frames, fork-lift build |
| Air capacity short | FRL sized to 150 NL/min peak |
| Uneven floor | Height feet + laser re-level |
| Grid fluctuation | 380 V/50 Hz with 220 V/60 Hz option, surge guard |
Line Maintenance Schedule
| Interval | Tasks |
|---|---|
| Daily | Drain all FRL bowls; check CPM vs target; test E-stop chain; clear reject lane |
| Weekly | Lubricate conveyors; clean coders; verify buffer sensors; belt tension |
| Monthly | Calibrate checkweigher; replace vacuum filters; torque frame bolts; backup PLC |
| Quarterly | Replace suction cups; grease gearboxes; verify PROFINET I/O; inspect palletiser |
| Annually | Gearbox oil; bearing swap; insulation test; full SCADA review; OEE audit |
Working with ZRAY
Review the full ZRAY product range for the cell that fits your carton and CPM. Our support team handles FAT, SAT and spare-parts planning, and you can contact ZRAY directly to start a requirement study and layout drawing.
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
Want To Know More About Our Upgraded Machines?
Send your carton specifications and output demand, our engineer will provide free technical scheme & quotation
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