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Industrial packaging solutions: FEFCO 410
This project features a fully automated industrial packaging line designed for FEFCO 410 box forming – from initial formation to final gluing – transforming a previously manual process into a continuous, high-performance flow.
At the push of a button, the system forms boxes in the selected format and transports them via a vacuum conveyor, eliminating manual handling and ensuring consistent throughput. Structural components such as partitions and honeycomb cores are inserted by two synchronized industrial robots, enabling precise and repeatable placement while maintaining uninterrupted production flow.
The process concludes with automated hot glue sealing – both end and edge – performed inline without stopping the line. Operating at speeds of up to 12 boxes per minute, the system delivers a significant increase in packaging efficiency while requiring only a single operator for supervision.
The results (FEFCO 410 packaging line)
Biggest challenges
Project in numbers
Operating Principle
Box forming
An automated unit forms boxes according to the selected format and transfers them directly into the production flow.
- At the push of a button, the selected box size is automatically formed
- Formed boxes are transported to the next stage via a vacuum conveyor
- Ensures consistent box geometry and uninterrupted flow
Parts and honeycomb inserting
A robotic cell inserts structural components such as partitions and honeycomb cores into the boxes without interrupting production.
- Two synchronized industrial robots ensure precise and continuous loading
- A primary robot picks components from stacks and positions them accurately inside the box
- Supporting conveyor system ensures stable and efficient component supply
- Main base conveyor
- Two roller conveyors for component stack feeding
- Roller conveyor for empty pallet removal
Box gluing with hot glue
The sealing process is performed inline in two continuous steps:
- End sealing
- Edge sealing
Hot glue is applied without stopping the line, ensuring strong bonding and maintaining continuous production flow.
Business impact
Beyond performance improvements, the client achieved a significant transformation in operational stability:
- Stable and predictable packaging flow
- Elimination of a key production bottleneck
- Reduced operational risk and human error
- Lower dependency on workforce availability
- Increased overall production capacity
The packaging stage is no longer a limitation — it is now a reliable, high-performance part of the production line.
Conclusion
By replacing manual handling with a fully automated and synchronized system, we transformed packaging from a bottleneck into a performance driver.
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