A Guide to Can Cartoning, Tray Packing and Variety-Pack Automation
Problem
Packaging beverage cans at high speeds requires more than simply transferring cans into a carton. The complete system must control product flow, manage infeed pressure, accurately group cans, erect packaging materials, and load each pack without damaging the product or interrupting production.
AFA Systems’ servo-controlled can cartoning technology is designed to address these requirements while providing manufacturers with the flexibility to run standard cartons, corrugated trays, and mixed-product variety packs on a single packaging platform.
Servo Control for Speed and Flexibility
The machine incorporates multiple servo-controlled axes to provide accurate, repeatable, and independently controlled machine movements.
Servo-driven technology allows each section of the machine to be electronically synchronized. This provides precise product handling while allowing operating parameters to be adjusted for different can sizes, pack patterns, carton styles, and production speeds.
Independent servo control can also simplify changeovers and reduce the number of mechanical adjustments required when changing products or package configurations.
The result is a packaging platform capable of delivering high-speed performance while maintaining the flexibility required for modern beverage production.
Reliable Can Control Considerations
One of the most important considerations in can cartoning is maintaining positive product control before the cans enter the carton.
Cans arriving from upstream filling and processing equipment may experience fluctuations in speed, spacing, and back pressure. Without proper control, these conditions can cause cans to bridge, tip, become misaligned, or create excessive pressure at the loading station.
AFA’s high-speed intermittent can-handling system uses a combination of:
- Static lane guides
- Rotary lane guides
- Pop-up lane-control devices
- Integrated back-pressure relief
These components work together to guide, separate, meter, and organize cans before loading. The system maintains orderly product flow while preventing excessive pressure from building within the infeed lanes.
Consistent control at this stage allows the product-loading system to form accurate can groups and transfer them smoothly into the carton or tray.
Integrated Can Recirculation
Back pressure is a common challenge on high-speed beverage packaging lines. When downstream equipment slows or pauses, cans can accumulate quickly at the cartoner infeed.
A built-in can recirculation conveyor helps remove excess product pressure from the main infeed. Rather than allowing cans to continue accumulating near the loading station, excess cans are peeled away and recirculated within the system.
This approach helps reduce:
- Can bridging
- Product jams
- Excessive pressure on cans and guide rails
- Infeed interruptions
- Unplanned machine downtime
By actively managing product accumulation, the recirculation system supports more stable operation and allows the cartoner to recover more effectively following short upstream or downstream interruptions.
Smooth and Controlled Carton Loading
Once the cans have been grouped into the required pack pattern, servo-controlled product loaders transfer the cans into the carton or corrugated tray.
The loaders are synchronized with the flight chains and product-feeding system to provide accurate timing throughout the loading cycle. Controlled servo motion allows the loading profile to be optimized for each product and package format.
This is particularly important when running lightweight cans, tightly packed configurations, or products that may be sensitive to sudden impacts.
Maintaining control throughout the loading process helps prevent damaged cans, stoppages and carton deformation.
Variety-Pack Packaging Capability
Consumer demand for mixed-flavor and variety-pack beverages continues to create new challenges for beverage manufacturers and contract packagers.
Traditional packaging systems are commonly designed to receive a single product from one production stream. A variety-pack operation must accurately introduce multiple products, establish the required assortment, and maintain the correct sequence throughout the loading process.
AFA’s system can be configured with optional variety-pack conveyors and additional loading stations. These modules allow multiple can flavors or product types to be introduced into the packaging process.
Depending on the application, the system can be designed to create pack configurations such as:
- Alternating flavors
- Multiple rows of different products
- Equal quantities of several can varieties
- Custom product sequences
- Promotional mixed packs
Servo-controlled loading stations provide the precision needed to maintain the selected variety-pack arrangement as the cans are transferred into the carton or tray.
This modular approach allows manufacturers to add mixed-pack capability while retaining the ability to run conventional single-product packages.
Open Frame Design for Access and Maintenance
Packaging equipment must be designed not only for production performance but also for the employees responsible for operating, cleaning, and maintaining it.
The machine features an open-frame, walk-in design with floor-to-ceiling access doors. This provides maintenance personnel with improved access to internal machine components.
The open construction supports:
- Faster cleaning
- Easier preventive maintenance
- Improved inspection of machine components
- More convenient access to wear parts
- Reduced maintenance-related downtime
- Better visibility during troubleshooting and changeovers
Designed for Wet Production Environments
Beverage packaging lines may be exposed to condensation, minor product leakage, and liquid residue from upstream filling operations.
The machine’s wet-environment design allows applicable components to be cleaned using low-pressure rinsing. This helps operators remove liquid and product residue from machine surfaces without relying entirely on manual wiping.
Wet-environment construction may include suitable component selection, corrosion-resistant materials, protected electrical devices, and frame designs that reduce areas where liquid can collect.
The specific cleaning procedure should always be based on the product being packaged, the machine configuration, and the sanitation requirements of the facility.
Selecting the Right Can Packaging Solution
Every can-packaging application has different requirements. Important considerations include:
- Can diameter and height
- Product stability
- Maximum line speed
- Pack count and arrangement
- Carton or tray style
- Variety-pack requirements
- Upstream product-delivery conditions
- Available floor space
- Cleaning requirements
- Future package formats
AFA Systems combines advanced servo technology, precise can control, and flexible machine configurations to engineer custom can cartoning solutions for standard, tray, and variety-pack applications.