An automated factory is only as automated as its most manual stage. A facility that has invested in robotic primary packaging, high-speed fillers, and automated conveyance , but still relies on operators to manually load and seal cases at the secondary packaging stage , has not completed its automation journey. That manual gap is both a throughput constraint and an OEE liability that compounds across every shift.
Case packaging systems close that gap. An integrated case packing system , from carton erector through robotic loading to palletizer , operates as a single, synchronised machine under one control architecture. It runs at the rated speed of the primary packaging line, switches between product formats on a recipe change, and detects quality failures before they become shipped defects.
This guide explains what a complete case packaging system includes, how the stages integrate, which configurations Cybernetik builds for different production profiles, and how to evaluate the right system for an automated manufacturing facility.
A case packaging system is an integrated secondary packaging line that spans five sequential stages:
The critical difference between a case packing system and a collection of standalone machines is the control architecture. A true case packaging system operates all five stages under a single PLC and SCADA layer, with a single recipe selection at the HMI governing format settings, speed parameters, and quality thresholds across every stage simultaneously.
When a format change is executed, it does not require an operator to walk to five different machines and update each one. The recipe propagates automatically , from the carton erector blank magazine setting to the robot’s gripper speed profile to the palletizer’s pallet matrix formation.
Integrated Secondary & Tertiary Bottle Packing System
Cybernetik builds case packaging systems for three primary product categories. Each configuration is engineered as a complete, integrated system , not a collection of separately specified machines.
Case Packing System for Pouches
Cybernetik’s Case Packer for Pouches is designed for flexible packaging lines producing filled pouches at up to 40 pouches/min. The staggered pouch lifting system and vibratory thickness conveyor are purpose-built subsystems that address the specific challenges of flexible pouch packaging , variable thickness, belt shifting, and density requirements , that generic case packers cannot resolve.
Parameter | Value |
Throughput | 40 pouches/min |
Payload | Up to 25 kg |
Key Mechanism | Staggered pouch lifting + vibratory thickness normalisation |
Quality Options | Broken pouch rejection, metal detector, pouch pressing |
Case Packing System for Bottles
Cybernetik’s Case Packer for Bottles is the primary case packaging system for beverage, food, personal care, and pharmaceutical bottle lines handling multiple bottle variants.
Parameter | Value |
Throughput | Up to 120 bottles/min or 5 cases/min |
Payload | 200 kg |
Bottle Variants | Up to 5 |
QC | Missing bottle detection + vision inspection |
Traceability | Track and trace standard |
Case Packing System for Shrink Packs
Cybernetik’s Case Packer for Shrink Packs is the highest-throughput case packaging system configuration , built for beverage canning and shrink multipack operations at up to 400 cans/min. Optional upstream carton erector and downstream taping/labelling complete the end-to-end automation sequence.
Parameter | Value |
Speed | Up to 400 cans/min |
Payload | 200 kg |
End-to-End Options | Case erector, top/bottom taping, labelling |
Dual-Mode Case Packing System , Shrink Packs and Bottles
Cybernetik’s Case Packer for Shrink Packs & Bottles provides a single-robot dual-mode system for factories running both individual bottles and shrink-wrapped multipacks , eliminating the capital cost and floor-space requirement of two separate case packaging systems.
Parameter | Value |
Speed (Shrink) | Up to 400 cans/min |
Speed (Bottles) | Up to 120 bottles/min |
QC Technology | 3D cloud point for missing bottle detection |
Case packaging is the penultimate stage of the end-of-line. The final stage , palletizing , must receive cases at the output rate of the case packer and stack them onto pallets without delay.
Cybernetik’s Box Palletizer range handles up to 1,200 boxes/hour (up to 1,800/hour for high-level configurations) and palletizes box variants arriving on separate conveyors onto distinct pallets within the same cycle. The Robotic Carton Palletizer simultaneously palletizes two cartons per cycle at 15 cartons/min with customisable matrix formation and an automated pallet dispenser for continuous operation.
Because both the case packer and palletizer operate under Cybernetik’s shared PLC/SCADA architecture, recipe changes at the case packer automatically update the palletizer’s stacking pattern , no separate operator intervention required at the palletizer HMI.
Explore the Box Palletizer Range
Parameter | What to Confirm |
Throughput range | Peak units/min with 15–20% headroom; matches both primary line output and palletizer input |
Product range | All active SKUs covered with one end-of-arm tool or auto tool changer |
Carton format range | All active case sizes covered by recipe-driven erector and sealer |
Integration architecture | Shared PLC/SCADA with upstream primary packaging and downstream palletizer |
Quality control scope | Missing unit detection, vision inspection, track and trace , all integrated, not bolted on |
Changeover method | Recipe-driven HMI , target under 10 min for all active format pairs |
Safety | Single interlock chain across full case packaging system |
Supplier scope | Full case packing system from one supplier , erector through palletizer |
An integrated secondary packaging line spanning case erection, robotic product loading, case sealing, labelling, and palletizing , all under a single PLC/SCADA architecture with unified recipe management.
A standalone case packer performs only the loading stage. A case packing system integrates all five stages under one control architecture , one recipe change updates all stages simultaneously.
Pouches, bottles, shrink packs, jars, aluminium cans, cartons, bags, chocolates, and more , across food, beverage, FMCG, pharma, and chemical industries.
By eliminating manual speed caps (availability), running at rated machine speed (performance), and detecting defective cases before sealing (quality) , typical OEE gain is 15–20 percentage points.
Yes. Cybernetik’s systems support OPC UA communication and PLC compatibility for integration with existing upstream primary packaging and labelling equipment.