Automated tea bag packaging machine boosts high-speed carton throughput
Project snapshot
Client:
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Challenge
High-speed, flexible carton packaging
Our customer produces tea bags for retail sale and required an automated system capable of applying secondary carton packaging at high speed to meet demanding fulfillment schedules. The solution needed to support multiple carton formats while maintaining high-quality standards and maximizing overall production throughput.
Innovation
Buffered, twin-lane secondary packaging architecture
Following an assessment of the customer’s existing production line, AIR identified opportunities to improve flow and resilience through targeted automation enhancements. A custom-designed buffering and twin-lane packaging solution was developed to support continuous, high-speed operation.
- Twin-lane carton packing system to increase throughput capacity
- Custom product buffer to decouple upstream and downstream processes
- Bypass and re-feed functionality to maintain line operation during interruptions
- Flexible handling to support multiple carton styles within a single system
Result
Increased throughput and improved line resilience
With the addition of the new automated secondary packaging machine, the customer can now pack up to four different carton styles at speeds of up to 120 packs per minute. The introduction of buffering and re-feed functionality also enables continuous operation of upstream equipment, even during downstream stoppages – significantly improving overall line efficiency and output consistency.
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