How a box erector fits into your packing line

A box erector takes a flat blank and forms it into an open carton with a closed bottom. The front and rear bottom flaps are closed first, followed by the two side flaps. This prepares the carton for filling.

AUTOBOX and AUTOBOX10 tape the bottom after folding the flaps. FLEX BOX only folds and holds the bottom flaps, and the case sealer tapes both the top and bottom after filling. The box erector is positioned at the start of the packing line, before filling and sealing.

The erector opens the flat, folded blank into a square tube and closes the bottom, leaving the top open for filling. If you form cartons by hand, each one requires folding and taping the bottom flaps before filling can begin. Using an erector removes this step from the packing table.

On a packing line, the usual sequence is to erect the carton, fill it, close and tape the top, then label, strap, or stack the carton on a pallet.

All three machines in this category work with standard cartons delivered flat, with the side joint already sealed by the carton manufacturer and four bottom flaps. The erector opens the flattened tube and closes the bottom, but does not make the side joint.

How the bottom is closed affects your packing line setup. A carton with a taped bottom from the AUTOBOX or AUTOBOX10 can move on a roller conveyor to a filling station further down the line, since the tape keeps the flaps closed during transport. A carton from the FLEX BOX has its bottom flaps only folded and held, so you fill it while it stands on the machine and send it directly to the case sealer after filling.

Automatic case erector models: AUTOBOX and AUTOBOX10

AUTOBOX pulls blanks from a sloped or horizontal worktable. Suction draws one blank at a time into the machine, which opens it, folds the bottom flaps, and tapes the bottom. It can process up to 16 cases per minute, depending on carton size. It features a Siemens PLC with a touch screen and is set to the carton size before starting. It uses BOPP or paper tape, 48 mm as standard.

AUTOBOX10 takes blanks from a magazine using suction cups. It erects 10–15 cartons per minute. The touch screen offers both automatic and manual modes and stores up to 10 carton sizes. A servo sets the carton width; guides, belts, and suction cups are adjusted by hand. It tapes the bottom with 50 or 60 mm tape, with 75 mm available on request.

With AUTOBOX, you stack flat blanks on the worktable. The sloped worktable holds about 80 double-corrugated blanks, while the horizontal one holds about 150. If you use thinner board, you can fit more blanks in the stack.

It handles cartons 250–530 mm long and 150–400 mm wide. Tape heads for 60 or 72 mm tape are available by special order.

AUTOBOX10 folds the front, rear, and side flaps of the bottom, then tapes it. The machine pushes the erected carton out on its belts; its manual mode operates step by step.

The carton size ranges of AUTOBOX and AUTOBOX10 overlap but are not the same. For example, a carton narrower than 200 mm fits only the AUTOBOX, which starts at 150 mm wide. A carton shorter than 250 mm fits only the AUTOBOX10, which starts at 200 mm long.

Both AUTOBOX and AUTOBOX10 continue running as long as there are blanks on the worktable or in the magazine. The operator’s role is to refill the blanks in time to keep the line moving. On AUTOBOX10, you can set a counter to stop the machine after a set number of cartons. For example, if you need to pack a fixed batch, the machine will stop automatically when the count is reached. Pressing Clear allows the machine to continue for the next batch.

The AUTOBOX10 includes a manual debugging mode, where each press of the step button advances one step of the cycle: taking the carton, folding the front flap, folding the rear flap, folding the side flaps, pushing the carton out, and resetting. There is also an ‘open a case’ function that erects a single carton. After changing sizes, you can use this function to erect one carton and check it before starting automatic operation. Make sure the corners are square, the flaps are closed flat, and the tape is centered.

On the AUTOBOX10, you enter the actual width of the carton for each stored carton number. When you select a carton number, the servo moves to that width. The conveying center point for this measurement is set at the factory and does not change.

Compare case erectors by type, size, and speed

The table below compares each case erector by type, carton size range, output per minute, how blanks are fed, and how the bottom is closed. Use it to see which machine matches your needs.

To use the comparison table, start by checking the carton size range for each machine to see which fits your cartons. Next, look at the output per minute to match the machine’s speed to your packing rate. The last two columns show how the blanks are fed (by the operator, from a worktable, or from a magazine) and whether the machine tapes the bottom or leaves taping to the case sealer. The AUTOBOX and AUTOBOX10 rows are the machines that tape the bottom.

FLEX BOX semi-automatic case erector: operator and machine

With the FLEX BOX, the operator takes a flat carton from the shelf, opens it, and closes the front and rear bottom flaps as the carton is placed on the machine. Two air cylinders fold the left and right bottom flaps and hold the bottom closed while the operator loads the carton.

A push button or foot switch activates a pusher that moves the filled carton into a case sealer, which applies tape to the top and bottom. The FLEX BOX produces 6–7 cartons per minute with an operator at each carton. The worktable height can be adjusted from 700 to 800 mm.

Once the carton is on the machine, it stays in place while the operator fills it. The FLEX BOX acts as both the forming and filling station. After filling, the operator folds the top flaps by hand.

Adjust the worktable height to match the case sealer and the operator. Set the carton length by moving the carton feeder and using the adjustment knob. The product page lists our semi-automatic case sealer as the compatible machine for the FLEX BOX.

The FLEX BOX is loaded while the carton stands on the machine, so its output of 6–7 cartons per minute includes the time for opening, loading, filling, closing the top flaps, and pushing the carton into the sealer. This means each carton takes about 9 to 10 seconds from start to finish. If the items to be packed are not ready, the output will decrease, since the next carton cannot be started until the filled one leaves the machine.

The air filter regulator controls the speed of the pusher that moves the filled carton into the sealer. The pusher should move the filled carton firmly but smoothly, without shifting the contents. Before starting work, make sure the FLEX BOX is level on stable ground, with the casters locked and covers in place. If the machine is not aligned with the case sealer, the pusher will send the carton in at an angle.

Carton sizes, tape widths, and changing sizes

To select the right machine, measure the smallest and largest cartons you pack, including length, width, and height. Compare these measurements with the ranges: AUTOBOX handles cartons 250–530 mm long and 150–400 mm wide, while AUTOBOX10 covers 200–500 mm long, 200–400 mm wide, and 150–350 mm high. For FLEX BOX, see the carton sizes listed on its product page.

For AUTOBOX10, also check two totals: the length plus width must not be more than 900 mm, and half the width plus the height must not be more than 550 mm. Check both for your largest carton.

Tape width is chosen when ordering. AUTOBOX uses BOPP or paper tape, 48 mm standard, with 60 or 72 mm tape heads available by request. AUTOBOX10 uses 50 or 60 mm tape, with 75 mm available if needed.

To change sizes on AUTOBOX10, select the stored carton number on the touchscreen. The servo sets the width, and you adjust the guides, belts, and suction cups by hand. Up to 10 carton sizes can be stored. AUTOBOX is set to the carton size before the run and can be built for other sizes if needed. Grouping orders by carton size reduces the number of size changes. Always check that the case sealer after the erector can handle all the sizes you run.

Always compare the size ranges to the erected carton, not the flat blank. The AUTOBOX10 manual asks you to confirm the size of the carton after it is formed before making any adjustments.

Changing sizes on the AUTOBOX10 follows a set order: reset the servo to zero, select the carton number, set the belts, adjust the magazine rails, set the carton bracket height, set the press guide plate height, adjust the forming positioning rods, set the forming bracket, adjust the suction cups, and finally set the push rod. Suction cups are set after the belts, rails, brackets, and rods, since their position depends on those settings. When switching from a larger to a smaller carton, lower the suction cup holder, as the press guide may block it. For a large carton, pull out the push rod without letting it touch the suction cup holder. None of these three machines adjusts itself automatically for each carton. If you run mixed carton sizes in the same hour, each size change requires a new setup.

Choosing a semi-automatic or automatic box erector

A semi-automatic box erector like the FLEX BOX is best for lower output or frequent size changes, since the operator works with each carton.

An automatic box erector such as the AUTOBOX or AUTOBOX10 forms and tapes each carton the same way, so the operator only needs to refill the blanks. These models are suited for a steady flow of cartons. The filling step determines the pace of the line: if the box erector produces more cartons than can be filled, a backlog will form. All three models can be adjusted for carton size within their range.

To choose the right machine, count how many cartons you pack during your busiest hour and how many people are available for the job. Compare these numbers with the speeds in the table.

Space is also important. The AUTOBOX measures 3045 × 1855 × 1300 mm with the sloped worktable and 3045 × 2444 × 1300 mm with the flat one. AUTOBOX10 is 2020 × 2080 × 1396 mm. Leave enough space around the machine for loading blanks and for maintenance access.

Calculate the time per carton to see if your filling and sealing steps can keep up. For the AUTOBOX10, 10–15 cartons per minute means one carton every 4 to 6 seconds. This is the rate at which open, bottom-taped cartons will be ready for filling.

With the FLEX BOX, one person opens, fills, and sends each carton into the sealer. With the AUTOBOX or AUTOBOX10, forming is separate from filling. Plan who will refill the blanks and where the open cartons will wait for filling.

An automatic erector requires someone who can set it up correctly. On the AUTOBOX10, a size change follows the adjustment steps in its manual. The cylinder and air settings should only be handled by trained staff.

Blanks, wear parts, and box erector adjustments

A box erector needs flat, dry blanks. Warped or damp blanks are difficult to pick, may open crooked, or jam in the machine. Store blanks flat, dry, and off the floor. Suction cups hold the blank with vacuum. Worn or dirty cups lose grip, so check them regularly on the AUTOBOX and AUTOBOX10.

On the AUTOBOX10, the belts should just touch the sides of the erected carton. If too tight, the carton will deform. If too loose, it will not be pushed out. The press plate should be about 5 mm above the carton. If set incorrectly, the bottom tape may have a gap or the carton may not exit the machine. A dull blade on the tape head will leave a rough cut.

The manufacturer of the AUTOBOX recommends keeping spare suction cups available.

If the main air regulator on the AUTOBOX10 cannot hold its set pressure, the air supply is too weak and the suction pick-up will not work. The blade and springs in the tape head are wear parts on the AUTOBOX.

On the AUTOBOX10, set the magazine rails so there is about a 5 mm gap between the flat carton and the side guide plate. This gap allows the carton to slide easily when picked up by the suction cups. Rails set too tight will hold the carton back in the magazine.

The AUTOBOX10 picks up the carton on its wider side, with the outer edge of each suction cup about 15–20 mm from the carton edge. Set the suction cups after adjusting the magazine rails, brackets, and positioning rods, or the pick-up will not work.

Set the forming bracket on the AUTOBOX10 to match the length of your carton. If it’s not set correctly, cartons may come out misshapen, diamond-shaped, damaged, or get stuck in the machine. Always make sure the erected carton is square before starting production. The thickness of the board also affects the forming process. The knobs on the cylinders control the push and return speeds, but only trained personnel should adjust these, and only after the forming positions and carton sensors are set. The AUTOBOX comes with a spare blade, extra tape-head springs, screws, and hand tools, so you can replace the first blade or spring right away if needed.

What affects the price of a box erector

The price of a box erector depends on whether it is semi-automatic or automatic, whether it tapes the bottom, the type of worktable, tape heads, and if carton sizes are custom-built. Operating costs include parcel tape, compressed air, and wear parts such as suction cups, the tape head blade and springs, and the belt.

FLEX BOX does not use tape itself, as taping is done by the case sealer after filling. Each product card has a Get offer button for requesting a quote, for example, if you want an erector together with a case sealer, and an Add to inquiry button to collect several products in one request.

For the AUTOBOX, a higher worktable or left-side blank feeding can be custom-built. If you need either option, mention it in the same inquiry as the machine.

With the FLEX BOX, a case sealer placed directly after it is part of the setup, since the bottom is taped only at that stage. With the AUTOBOX or AUTOBOX10, you can use your existing case sealer to close the top, as long as it fits the same carton sizes. Wear parts on the AUTOBOX include more than just suction cups and the tape head: the manufacturer’s list also covers the vacuum generator, cylinders, linear bearings, and valves.

Compressed air, power, and safety with box erectors

All three box erectors require compressed air and electrical power. FLEX BOX operates on 220 V, 50 Hz, 600 W. AUTOBOX uses 220 V single phase, 50/60 Hz, 400 W. The air unit needs regular attention: drain water from the air filter often. Always turn off the power and air before working on a box erector. Do not wear loose sleeves, ties, rings, or watches near machines with belts and moving arms.

AUTOBOX10 begins its automatic cycle only after the servo returns to zero and the cylinders are at their starting position. FLEX BOX will shut down if the control panel is opened during operation. Lubricate the FLEX BOX bottom drive chain once a week and check bolts and screws regularly.

FLEX BOX uses compressed air for the flap cylinders and the pusher, while AUTOBOX and AUTOBOX10 use it for their cylinders and suction pick-up. Plan for an air line at your packing station.

The AUTOBOX10 stops automatically when the carton counter reaches the set number. Pressing Clear allows it to continue. Only trained staff should adjust its pneumatic valve settings.

AUTOBOX10 maintenance includes cleaning, lubricating moving parts, checking air pressure, and inspecting suction cups and belts for wear.

On the AUTOBOX, the suction cups get vacuum from a vacuum generator powered by compressed air. If the air supply is weak, cartons may not be picked up, as the AUTOBOX10 manual also notes.

The AUTOBOX has IP54 electrical protection, meaning it is protected against dust and splashing water. Its noise level can reach up to 75 dB.

Before making any adjustments on the AUTOBOX10, turn off the power, disconnect the air, and clear the area around the machine. If someone is caught by a moving part like a belt, turn off the power first, then free the person. The FLEX BOX plugs into a socket, not hardwired. Its power switch should be off before connecting, and the emergency switch is checked when connecting the air. The AUTOBOX10 position teaching screen is password-protected. Keep the login with the responsible person.

Checklist before buying a box erector

Before buying a box erector, check your carton sizes: length, width, height, smallest and largest. Know your peak hourly carton output, how many sizes you run, and how often you change them. Check the parcel tape width you use, the compressed air and power available at your packing area, and the space for the machine.

Decide on the direction of flow and the height of tables and roller conveyors. The case sealer after the box erector must handle the same carton sizes. A roller conveyor between the box erector, the filling station, and the case sealer moves the open cartons. These points help you match the machine to your packing line.

Count how many cartons you need to pack per hour at peak times. Decide if you want an operator at the machine, as with FLEX BOX, or if you need an automatic erector like AUTOBOX or AUTOBOX10.

Pay attention to the direction of flow. AUTOBOX takes blanks in from the right and sends cartons out to the left as standard. The opposite direction can be custom-built.

Match the heights of your equipment: FLEX BOX worktable adjusts from 700 to 800 mm, AUTOBOX is 650 mm as standard and up to 1000 mm custom-built, AUTOBOX10 is 650 mm. Choose the tape width when ordering. The AUTOBOX is rated for -10 to 40 °C and humidity up to 98 percent, so check if your shipping area stays within these limits.

If your new machine will work with a case sealer you already own, include that sealer’s model and working height in your inquiry. This way, carton sizes and heights can be checked for both machines.

Questions about case erectors

Which case erectors tape the bottom of the carton?

AUTOBOX and AUTOBOX10 both tape the bottom of the carton after folding the flaps. FLEX BOX does not tape the bottom; it only folds and holds the flaps.

Do these case erectors need compressed air?

All three case erectors in this category require compressed air to operate. This is needed for functions like suction, folding flaps, or driving the pusher.

How many cartons per minute can each case erector produce?

FLEX BOX produces 6–7 cartons per minute with an operator. AUTOBOX10 produces 10–15 cartons per minute. AUTOBOX can make up to 16 cases per minute, depending on the carton size.

Can one case erector handle different carton sizes?

Yes, each case erector can be set for different carton sizes within its range. AUTOBOX10 stores up to 10 carton sizes and uses a servo to set the width. AUTOBOX is set to the carton size before each run. FLEX BOX is adjustable to the carton size.