up to 36,000 units/h at the infeed

Packing and Palletizing Solution

The final section of the line: group packing into shrink film or cases, palletizing and wrapping. This is where overall line throughput is most often lost.

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Group packing: PE shrink film, tray + film, cardboard case
Pack patterns: 2×3, 3×4, 4×6, 3×5 and custom to spec
Output: up to 36,000 bottles/h at the infeed
Palletizing: Gantry palletizer or robotic arm
Palletizer speed: up to 120 pallets per shift
Wrapping: Pallet wrapper with film pre-stretch
Marking: Case and pallet label applicator
Control: PLC with recipes for SKU and pack patterns

About the solution

The packing section must run faster than the filler — otherwise the line stops on accumulation. We build in a 10–15 % throughput margin and buffer accumulators ahead of every machine.

The packing scheme is chosen to match the sales channel: a 2×3 or 3×4 shrink multipack for retail, a cardboard case for distribution, a tray with film for HoReCa. Palletizing is done by a gantry palletizer or a robotic arm.

Built into the design

Cycle-time margin

Each machine in the section outpaces the previous one — packing never slows down filling.

Fast pattern changeover

The pack pattern is stored as a recipe: switching between case formats requires no mechanical adjustment.

Robot instead of gantry

The robotic arm takes up less space and can serve several lines at once.

Pack-quality control

Checking that every bottle is present in the pack, film-seal integrity and correct pallet pattern.

Line composition along the product flow

7 positions along the product flow. Every unit opens in the catalog: series, specifications, scope of supply and a quote request.

Full equipment catalog

Line model selection

Selecting a group packaging method

The packaging method determines block stability during transport and packaging material cost per container.

Packaging method	Material	Applicability	Output
PE film shrink wrap	polyethylene film	up to 3,000 btl/h (semi-automatic)	up to 3,000 btl/h
PE film shrink wrap	polyethylene film	automatic line	up to 12,000 btl/h
Shrink wrap with tray	film + cardboard tray	heavy or tall containers	up to 9,000 btl/h
Wrap-around case	corrugated cardboard	premium packaging, branding	up to 6,000 btl/h
Corrugated case (case pack)	corrugated cardboard	glass, cans, heavy containers	up to 6,000 units/h

For containers with a high center of gravity (glass, large PET), packaging with a tray or a case is recommended instead of plain shrink wrap.

Palletizing

Parameter	Value
Stacking method	robotic arm or layer-based mechanical palletizer
Pallet height	up to 2.2 m (agreed to match transport and warehouse)
Interleaf sheets	cardboard between layers on request
Wrapping	pre-tensioned stretch film, top press
Output	up to 120 pallets/shift depending on the model

The stacking pattern (number of cases per layer, orientation) is programmed for a specific SKU and stored in the controller memory.

Line process flow

The choice of packaging solution depends on container type and transport stability requirements: lightweight PET containers usually go into shrink film, heavy glass and large cans into corrugated cases or wrap-around packaging, and a palletizer with stretch wrap completes the line.

Key features of the packing module

Electronic piece counting of containers before forming the block - no losses or excess film
Shrink tunnel with even temperature distribution across the full width of the block
Fast changeover of stacking patterns (1×2, 2×3, 3×4, 4×6) via recipes on the operator panel
Case forming from a die-cut flat blank matching the customer's brand
Interleaf cardboard sheets between pallet layers for heavy glass containers
The robotic palletizer stores several stacking algorithms for different container types
Pre-tensioned stretch wrap with a top press - the pallet keeps its shape during transport

Layout for lightweight containers in large batches: water, CSD, juice, canned goods.

1Forming a row and block of containers with an electronic counter
2Film feed and wrapping the block
3Shrink tunnel
4Block cooling on the outfeed conveyor
5Date coder / batch marking of the block (optional)
6Forming a layer of blocks on the pallet table
7Robotic palletizer: layer-by-layer stacking
8Pallet stretch wrap

Key line stations

What sits behind the nameplate output: contact-part execution, operating logic and service points for every station.

Group packing and palletizing

Line output

Shrink-wrap or corrugated case packing — format to retailer requirements.
Palletizer with layer-by-layer stacking to a set pattern, robotic option for limited floor space.
Pallet wrapper with film pre-stretch: lower film consumption, the pallet withstands transport.
Finished-pallet count and SSCC label printing at the output.

This station's equipment in the catalog

Core machines of the line

Equipment of the “Packing and Palletizing Solution” layout: each tile opens the catalog with series, specifications and a quote request for that machine.

Semi-automatic shrink wrap packer

Manual assembly of the container block followed by automatic film shrinking - a solution for lines up to 3,000 btl/h or where labor cost is low.

Automatic PE film wrapper

Group packaging of round, square or flat containers into shrink film with electronic piece counting and a shrink tunnel.

Half-tray wrapper

Containers are placed on a cardboard tray before film shrinking - improved block stability during transport and stacking.

Wrap-around case packer

The case is formed around the grouped containers from a die-cut flat cardboard blank - holds shape better than film and suits branding needs.

Case packer

Case forming from a flat blank, bottle loading by manipulator or guide rails, tape sealing.

Robotic palletizer

Layer-by-layer pallet forming with interleaf sheets according to a set stacking algorithm - stores several patterns in memory for different container types.

Depalletizer

Removes empty returnable containers or case blanks from a pallet and feeds them to the line without manual labor.

Pallet stretch wrapper

Wraps the formed pallet with pre-tensioned film and a top press - the pallet reaches the warehouse without shifting or losing packaging.

Auxiliary systems of the line

The engineering utilities without which a line never reaches its rated output: water and product preparation, sanitation, container handling.

Accumulation and grouping

The packing area inlet.

Accumulation table or buffer loop smooths out packing-line stops
Grouping into a defined matrix: 2×3, 3×4, 4×6
Servo-driven dividers and pushers, gentle container handoff
Count sensors and group-completeness checks before packing

Shrink-wrap and case forming

Forming the transport pack.

Heat tunnel with heating and cooling zones, adjustable for film thickness
Choice of cardboard tray, wrap-around or shelf-ready case
Hot-melt gluing with spot application to save adhesive
Format change via panel recipe and guide-rail repositioning

Palletizing

The line's handoff to the warehouse.

Gantry or robotic palletizer with layer-by-layer stacking
Stacking patterns for Euro pallets and non-standard sizes
Automatic pallet and slip-sheet feeding between layers
Wrapper with pre-stretch film and a top-press plate

Coding and inspection

Case label and SSCC pallet label.

Inkjet or laser coder: date, shift, batch number, traceability code
Fill-level, cap presence and seating inspection with automatic reject to a pocket
Good/reject product counters logged per shift hour
Ready for mandatory marking: case and pallet aggregation at the line outfeed

Conveying systems

Roller and chain conveyors for finished product.

Air conveyor for empty containers with air filtration and neck guide rails
Slat-top conveyor with independent drives and accumulation buffers between stations
AISI 304 frame, Siemens / Schneider drives and controls, Sick photo sensors
Photoelectric jam detection with automatic section stop before a line stoppage

FAQ

Shrink film or case?

Film is cheaper and faster; a case protects the product better in long-haul logistics and is more convenient at the retail checkout format. Lines often provide for both options.

Do we need a robot, or is a gantry enough?

A gantry palletizer is cheaper and simpler to maintain for a single pack pattern. A robot pays off when there are many patterns or it serves two lines at once.

How much does the Packing and Palletizing Solution cost?

Price on request: the budget depends on output, container type, line composition and the level of automation. After a short brief we send a preliminary estimate within 1–2 working days and a full quotation broken down by machine within 3–5 days.

What are the delivery and commissioning lead times?

Standard machines ship 8–12 weeks after the specification is confirmed, complete lines 12–20 weeks. Transport takes 2–6 weeks depending on the route; installation and commissioning on site take 2–4 weeks, with operator training included.

What output does this line reach?

The working range is up to 36,000 units/h at the infeed. Exact output is confirmed against your container, product and shift plan: we calculate the line balance and keep a margin on the bottleneck machine.

Request a quote: Packing and Palletizing Solution

Tell us the product, the container and the target output — we will return the line composition, a layout, a budget range and a delivery schedule.

Services for this line

Engineering, logistics, installation and service that turn this line into a working production site.

Engineering services

Process line design

Technology, specification, layout, throughput and utility calculations. The document equipment is ordered against and installation is carried out with.

Line installation and commissioning

Supervised installation, piping, electrics, PLC/SCADA automation, ramp-up to rated output and staff training. We hand over the line with a signed FAT/SAT certificate.

Service, maintenance and warranty around the clock

Scheduled maintenance, a spare parts warehouse, emergency call-outs, remote PLC diagnostics. SLAs are fixed in the contract — line downtime is measured in hours, not days.

Equipment supply and logistics

Contracts, customs clearance, insurance, multimodal delivery "to the workshop door" anywhere in the world — CIS, Europe, MENA, Asia.

Site selection and construction works

We help choose a plot or existing building, connect utilities, prepare the master plan and manage construction — from groundbreaking to workshop handover.

Digital layer

Any line can be supplied with a digital layer

SCADA, MES, OEE monitoring, batch traceability and integration with plant systems — engineered together with the line, not bolted on later.

Production digitalization How we work: customer portal