Conventional Case Packers vs. Robotic Case Packers: A Comparison

Feb 25

4 min read

Introduction

Case packers play a crucial role in a packaging line, ensuring efficiency and consistency packing products into cases or trays. With technological advancements, businesses now face a critical decision: choosing between conventional case packing machines and robotic case packing machines. Each type has its own strengths, making it essential to understand the differences and determine which best suits your production needs.

In this post, we compare conventional and robotic case packers based on efficiency, flexibility, cost, maintenance, and suitability for various industries.

What Are Conventional Case Packers?

Conventional case packers are automated systems designed to pack products into cases or trays using mechanical, pneumatic and servo based systems. These machines typically operate on fixed, pre-programmed motions, relying on mechanical arms, conveyors, and guide rails to achieve precision in packaging.

Advantages of Conventional Case Packing Machines

Cost-Effective for High Volumes – Conventional case packers are often more affordable initially and provide consistent high-speed operations, making them ideal for large-scale productions.
Proven Reliability – With years of industry use, these machines are known for their reliability, durability, and ability to handle repetitive tasks with minimal downtime.
Simple Operation – They are easy to operate, requiring only minimal training for workers to manage the machinery.
High-Speed Processing – Conventional machines operate at a consistent speed, often outperforming robotic systems in cases in throughput where extreme precision and customization are not required.

Disadvantages of Conventional Case Packing Machines

Limited Flexibility – These machines work best with standardized packaging and struggle with irregularly shaped products or frequent product changeovers.
Higher Labor Involvement – Operators may need to adjust the machine manually for different product sizes, leading to higher labor costs and slower transitions. This can be mitigated by higher end conventional case packers offering tool-less or automated change over features.
More Downtime for Reconfiguration – If production requirements change, reconfiguring a conventional machine can be time-consuming and costly if new change parts are required to be designed and built.

What Are Robotic Case Packing Machines?

Robotic case packers typically employ 1-3 off-the-shelf robots, add custom end of arm tooling and integrate them into custom pick and place stations. These machines can use a variety of sensors, vision systems, tooling and artificial intelligence to adapt to different product types and packing formats.

Advantages of Robotic Case Packing Machines

Unmatched Flexibility – Robots can be reprogrammed and retooled quickly, making them ideal for facilities that handle diverse products and frequent changes.
Increased Efficiency – With AI and vision technology, robotic case packers can identify and adjust to product variations, reducing errors and waste.
Improved Accuracy and Consistency – Robotic systems offer precise product placement, reducing damage and ensuring uniform packaging quality, although in some applications conventional case packers can meet the same standards.
Future-Proof Investment – As consumer demands shift, robotic machines provide adaptability, allowing businesses to respond quickly to market changes.

Disadvantages of Robotic Case Packing Machines

Higher Initial Cost – The upfront investment in robotic systems had been significantly higher compared to conventional machines, although this gap is shrinking, and is now non-existent in certain applications.
Complexity in Maintenance – Maintaining and troubleshooting robotic systems requires specialized skills. Not all businesses will have these skills in house and may need to be more reliant on specialized contractors for maintenance and troubleshooting. Robot program interfaces have drastically improved recently and often will integrate into traditional PLC's seamlessly.
Slower for Some High-Speed Applications – In scenarios where high speed or high payload is required without flexibility, traditional case packers may outperform robotic alternatives.

Key Factors to Consider When Choosing Between Conventional and Robotic Case Packers

When selecting the right case packing solution for your business, consider the following factors:

1. Production Volume & Speed

If your facility requires high-speed production with minimal variation, a conventional case packing machine may be the better choice.
If flexibility and customization are critical, a robotic case packing machine will offer better long-term value.

2. Product Variety & Changeover Frequency

Conventional case packers are best for facilities with standardized packaging.
Robotic case packers excel in environments where product sizes, shapes, or packaging formats frequently change.

3. Cost Considerations

If you have a limited budget and need a simple solution, conventional machines may be a more cost-effective option, although this cost gap is becoming negligible in many applications.

4. Maintenance & Operational Expertise

Conventional case packing machines require simpler maintenance but may have higher labor costs if extensive size and format changes are required.
Robotic case packing machines need skilled technicians for maintenance and trouble shooting.

5. Industry-Specific Requirements

Food & Beverage: Robotic machines are increasingly popular due to hygiene standards and adaptability to different packaging needs. They are well suited for flexible packaging applications; however, conventional case packers may have the upper hand in high payload, high throughput rigid applications, such as can and bottle lines.
Pharmaceuticals: Precision, low payload requirements and quality control make robotic systems an excellent choice.
Consumer Goods: Both options work well, but the choice depends on product variety and production volume.

Conclusion: Which One Is Right for Your Business?

Both conventional and robotic case packing machines have their place in modern manufacturing. If you prioritize speed, cost-effectiveness, and standardized production, a conventional case packing machine is likely the best choice. However, if flexibility and future scalability are important, investing in a robotic case packing machine is a smarter long-term decision.

By carefully assessing your production needs, budget, and operational goals, you can select the best case packing solution that maximizes efficiency and profitability for your business.

Optimize Your Packaging Line Today

Are you looking to upgrade your case packing system? Explore the Fertender catalogue, or contact our industry experts to explore the best solutions tailored to your business needs.