Case Studies

Bottles

Bottles, vials and ampules of all shapes and sizes are just one of our specialties.


View P100 Cartoner
Our Solution

The P100 Balcony Cartoner is the perfect machine for any project that includes bottles. It offers unmatched versatility, easy maintenance, rapid, repeatable changeovers and robust construction. It allows us the flexibility to carton many different sized bottles on one machine with very few change parts.

The P100 has been very successful with round and oval shaped bottles running at speeds up to 350 cartons per minute. Leaflets can be added flat in the bucket or "U" shaped around the bottle's cap during loading. Our bucket gripper ensures that the leaflets will be perfectly placed into the carton time after time.

We have developed a bottle collation system that is flexible enough to handle many different sized bottles. This modular collator was designed specifically for use with a leaflet feeder. Bottles are indexed into the cartoner with a timing screw system and gently laid down into the horizontal position for loading. Bar code reading is available as well as UV sensing or visual inspection.

Project Details
  • P100 Balcony Cartoner
  • Color Touchscreen Interface
  • Hot Glue & Reverse Tuck Closing
  • Soft Reject for Non-Loaded Bottles
  • Timing Screw Bottle Infeed System
  • Validation Made Easy
Project Options
  • Custom Collation System
  • Leaflet Feeder
  • “U” Fold Leaflet Assembly
  • Deboss Coder
  • Inkjet Printer
  • Laser Printer
  • Bar Code Scanners
  • Vision System


Bottles And Blisters

View P100 Cartoner
The Challenge

A leading nutraceutical company needed a machine that was capable of packaging both blisters and bottles into cartons. The flexibility of the P100 Balcony Cartoner along with many years of industry experience allowed us to build the perfect solution.

Our Solution

The P100 Balcony Cartoner was the perfect machine for this project. It offers unmatched versatility, easy maintenance, rapid repeatable changeovers and robust construction. It allowed us the flexibility to carton either blisters or bottles with very few change parts.

We engineered a custom collation system that was flexible enough to handle either blister cards or bottles. The collator was designed specifically for use with a leaflet feeder.

Bottles

Bottles were indexed with a timing screw feeding system. A pre-folded leaflet was placed flat in the bucket and the bottles were oriented horizontally into the infeed bucket in time with the leaflet. The product was gently loaded into the cartons which were then closed and sealed with hot glue or tuck closing and discharged from the machine.

Blisters

Blisters were indexed into the buckets with the correct count by a rotary blister card placer. A pre-folded leaflet was placed flat in the bucket in time with the blister card stacks. The product was gently loaded into the cartons which were then closed and sealed with hot glue or tuck closing and discharged from the machine.

Project Details
  • P100 Balcony Cartoner
  • Color Touchscreen Interface
  • Hot Glue & Reverse Tuck Closing
  • Soft Reject for Non-Loaded Bottles
  • Rotary Blister Card Placer
  • Timing Screw Bottle Infeed System
  • Leaflet Feeder
  • Validation Made Easy
Project Options
  • Custom Collation System
  • “U” Fold Leaflet Assembly
  • Deboss Coder
  • Inkjet Printer
  • Laser Printer
  • Bar Code Scanners
  • Vision System


Cases & Trays

The P200 Balcony Casepacker is a very versatile machine. It is capable of running cases and trays on the same machine with a rapid, repeatable changeover.

High-Speed Vial Cartoning

View P100 Cartoner
The Challenge

A major pharmaceutical company came to Serpa with a very difficult project. They had an application for 12 different sized vials with many different insert combinations in 12 different pack patterns, and they wanted them all to run on one machine. If we could provide the solution, they would buy two machines.

Our Solution

The P100 Balcony Cartoner was the perfect machine for this project. It offers unmatched versatility, easy maintenance, rapid repeatable changeovers and robust construction. Nobody else in the industry could satisfy all of the project requirements with one machine.

We engineered a custom collation system that was flexible enough to handle all of the different pack patterns. The collator used positive product handling to ensure there was no damage to any of the product. The collator was designed specifically for use with a leaflet feeder.

Vials are side transferred onto the infeed conveyor that takes them to the starwheel transfer which then puts them into the buckets. A second feeding system then optionally places a small bottle into the bucket and a gentle lay down device lays the bottles horizontal into the buckets. A pre-folded leaflet is placed into the bucket gripper and formed into a U fold around the vials during loading. The needles and blister pack are then hand loaded into the bucket. The product is gently loaded and the carton is closed and sealed with hot glue or Tuck and discharged from the machine.

Project Details
  • P100 Balcony Cartoner
  • Color Touchscreen Interface
  • Hot Glue & Tuck Closing
  • Soft Reject for Non-Loaded Vials
  • Starwheel Vial Infeed
  • Leaflet Feeder
  • “U” Fold Leaflet Assembly
  • Validation Made Easy
Project Options
  • Custom Collation System
  • Timing Screw Bottle Infeed System
  • “U” Fold Leaflet Assembly
  • Deboss Coder
  • Inkjet Printer
  • Laser Printer
  • Bar Code Scanners
  • Vision System


Cases And Trays

The P200 Balcony Casepacker is the only machine to truly run cases and trays. We provided this solution for a leading pharmaceutical company and they were so happy they bought a second machine from us.


View P200 Casepacker
The Challenge

An international healthcare company needed a custom solution to package many different sized bundles with several pack patterns into six different sized cases. They wanted to accomplish all of this on one casepacker. If we could provide the solution, they would replace all of the casepackers in their facility.

Our Solution

The P200 Balcony Casepacker was the ideal machine for this project. It offers unmatched versatility, easy maintenance, rapid repeatable changeovers and robust construction. No other company in the industry could truly run cases and trays on one casepacker.

Cartons

Individual cartons arrive on the infeed conveyor with the wide edge leading. A case is erected and presented for loading. The cartons are stacked and grouped using a progressive stacking system and transferred into the load area. A case is pulled from the magazine and erected in the load station. The cartons are gently loaded into the case. The case flaps are folded and sealed using pressure sensitive tape and discharged from the machine. The cases are then labeled using a print and apply system. The labels are inspected with a vision system and the cases are checked for weight. All good cases are then conveyed to a hand palletizing station.

Bundles

Bundles are fed to a single lane side push collator. They are grouped and the odd product is rotated and positioned for loading. A tray is pulled from the magazine and placed into the load area. The bundles are gently loaded into the trays and the flaps are folded and sealed using hot glue. The full trays are discharged from the machine. The trays are checked for weight. All good trays are then conveyed to a hand palletizing station.

Project Details
  • P200 Balcony Cartoner
  • Color Touchscreen Interface
  • Tape Case Sealing
  • Hot Glue Tray Sealing
  • Progressive Carton Upstacker
  • Bundle Collation and Rotation
  • Print & Apply Case Labeler
  • Vision System with Touchscreen Interface
  • Checkweigher
  • Validation Made Easy
Project Options
  • Case Upender
  • Custom Collation System


Automatic Changeover

Every machine Serpa Packaging builds is available with our automatic changeover option. Changeover can be accomplished with the push of a button in as little as 7 seconds depending on machine model, product and collation.

Large Bundles of Diapers

View P200 Casepacker
The Challenge

An international healthcare company needed a custom solution to package many different sized bundles with several pack patterns into six different sized cases. They wanted to accomplish all of this on one casepacker. If we could provide the solution, they would replace all of the casepackers in their facility.

Our Solution

The P200 Balcony Casepacker was the ideal machine for this project. It offers unmatched versatility, easy maintenance, rapid repeatable changeovers and robust construction. No other company in the industry could satisfy all of the project requirements with one casepacker.

We developed a custom collator for this application that included a stacker and two different turrets to achieve the desired pack patterns. The collator was designed to take up the minimum amount of floor space and give them the flexibility to add different products, cases and pack patterns in the future without any retrofitting to the machine. In the end, the collator did not take up any more floor space than our standard collation system.

The bundles of product entered the infeed conveyor with the fin seal trailing and laying on its side. Depending on what product was being run and the pack orientation, product may need to be bump turned. Product entered the collator and, depending on the pack pattern, was stacked, rotated and/or upended then gently loaded into the erected case. The flaps were closed and sealed using pressure sensitive tape.

Project Details
  • P200 Balcony Cartoner
  • Color Touchscreen Interface
  • Bump Turn Infeed
  • Custom Collation System
  • Product Upstacker
  • Stack Rotating Turret
  • Tape Case Sealing
  • Case Upender
  • Validation Made Easy