Against the backdrop of booming intelligent upgrading in the domestic manufacturing sector, Wuxi Chuansfo Intelligent Packaging Co., Ltd. has successfully launched and put into full operation a highly customized unmanned post-packaging production line, achieving a remarkable threefold improvement in overall packaging efficiency. This launch represents a key milestone in the intelligent and automated upgrading of China’s packaging manufacturing industry. The advanced production line integrates core technologies including robotic automation, 3D vision recognition, IoT connection and big data analysis, and is perfectly compatible with Horizontal Flow Wrapper equipment while optimizing the overall Horizontal Packing Machine Flow, realizing full-process unmanned operation from product offline packaging, carton processing, labeling and quality inspection to final palletizing and intelligent warehousing.
Core Technological Innovation: Six Intelligent Modules Form a Closed-Loop Packaging System
Spanning 68 meters in full length, this customized post-packaging line adopts a modular integrated design, consisting of six core intelligent functional modules to build a fully closed-loop, efficient and stable packaging operation system, covering all key links of post-production packaging:
The intelligent flexible feeding system is equipped with 3D vision-guided industrial robots, which can independently identify products with different specifications, sizes and shapes, and complete accurate grabbing and positioning. It supports mixed-flow production of multiple types of products on a single line. Verified by on-site operational tests, the system boasts a product recognition accuracy of 99.7% and a robotic grabbing success rate of 99.5%, laying a solid foundation for stable full-line operation.
The core packaging and carton sealing module delivers professional automated packaging solutions, configured with high-speed servo carton openers, high-precision six-axis robotic arms, as well as dual optional configurations of Semi Automatic Case Sealer and Custom Case Sealer. It can flexibly meet the standardized and personalized carton sealing needs of different industries and product types. The equipment can process 1,200 standard cartons per hour, lifting comprehensive packaging efficiency by 300% compared with traditional manual operation modes. Meanwhile, the system can automatically lay customized cushioning materials according to product attributes, effectively reducing the product breakage rate to below 0.2%.
The high-precision dynamic labeling workstation integrates intelligent inkjet printing and RFID writing equipment, endowing each packaged product with an exclusive digital identity label. It supports real-time data docking with the enterprise ERP system, realizing full-chain traceability management covering raw material procurement, production and processing, packaging detection and terminal sales.
The intelligent quality inspection module applies mature deep learning algorithms, which can synchronously detect 12 key indicators such as packaging integrity, label pasting accuracy and printing definition. The automatic screening accuracy for unqualified products exceeds 99%, thoroughly solving the problems of missing inspection and misjudgment in traditional manual quality inspection.
The adaptive automatic strapping station can intelligently adjust strapping tension and spacing parameters according to carton dimensions and packaging weight. Matched with energy-saving winding and packaging equipment, it completes stable pallet fixing and sealing, reducing the consumption of packaging consumables by 15% compared with traditional packaging processes.
The intelligent warehousing docking system realizes seamless connection between packaging and warehousing links. Through the cooperative operation of palletizing robots and AGV handling vehicles, finished packaged products can be automatically sorted and stored, and the WMS system updates inventory data in real time to ensure accurate and efficient warehouse management.
Remarkable Economic Benefits: Greatly Reduced Labor Costs and Improved Production Capacity
The official commissioning of this high-speed intelligent post-packaging equipment line has completely optimized the enterprise’s packaging production model. The number of on-site manual operators required for the entire packaging process has been reduced from 35 to only 2, with manual participation rate dropping below 5%. The single-shift daily packaging capacity has surged from 30,000 cartons to 100,000 cartons, while the product loss rate has dropped from the original 1.5% to 0.3%.
In addition, the automated packaging line solutions feature ultra-high production flexibility. The whole line only needs 15 minutes to complete product specification switching and production parameter adjustment, which is far more efficient than the 4–6 hours required for traditional production line retooling, greatly improving the enterprise’s rapid response capability for diversified and customized order demands.