Steven Douglas Corp. (SDC) was tasked with a new challenge from a returning customer. Adding to their production line of hose clamp manufacturing, they needed an automated way to package hose clamps into cartons to supply retail stores. This machine needed to pack 10 clamps per carton and work with 10 different clamps and three carton sizes with quick changeover capabilities.
This machine needed to erect and fill cartons with an exact number of parts before being closed and weigh checked for accuracy.
SDC designed and built an automatic cartoning machine to help a returning customer pack different sizes of industrial hose clamps into cartons. This system was designed with the functionality to switch from fully automated to semi-automated depending on the carton size with easy tooling changeover. Some key capabilities on this machine include:
This custom automated packaging machine runs up to 25 cartons per minute with tooling changeovers in 30 minutes.
This advanced packing system is engineered to drive operational efficiency, reduce labor costs, and improve output quality. By supporting multiple carton sizes with high-speed, partially and fully automated processes, businesses can significantly increase throughput—up to 25 cartons per minute—while maintaining accuracy through integrated sensors and weight checks. The quick tooling changeover minimizes production downtime, enabling faster response to changing packaging needs. Overall, the system helps reduce manual handling, improve consistency, and support scalable growth, resulting in lower operational costs and enhanced customer satisfaction.
For Carton Sizes 1–2 (Fully Automated):
For Carton Size 3 (Semi-automated):
Designed to balance flexibility with dedicated tooling, the SDC Rotary Cartoner is perfect for businesses looking to enhance their packaging operations, optimize space usage, and increase throughput. It allows for quick process parameter changes while limiting the complexity that can slow down changeovers and are custom-built to fit specific carton sizes and application needs.
The successful implementation of the automatic cartoning machine by Steven Douglas Corp. (SDC) represents a significant advancement in the customer’s hose clamp manufacturing process. By integrating key technologies like the SDC Rotary Cartoner, Bellco centrifugal feeder, and CTM labeling systems, SDC delivered a tailored solution that met the challenge of packaging multiple product sizes with speed and accuracy. The system’s flexibility, including quick-change tooling and efficient workflow, allows the customer to adapt to varying retail demands while minimizing labor and downtime.
The impact of this solution extends beyond automation—it enhances overall operational efficiency and quality control. With capabilities such as high-speed labeling, precise part counting, and post-packaging weight verification, our customer now benefits from a streamlined process that ensures consistent product presentation and compliance with retail standards. This case study underscores SDC’s ability to reduce engineering risks and deliver scalable, efficient packaging systems that improve throughput, adaptability, and long-term productivity.
A: This custom cartoner was designed to handle 10 different hose clamp types and three chipboard carton sizes. The system accommodates both consumer product packaging and industrial applications. Carton sizes 1 and 2 are run on a fully automatic cartoning process, while size 3 operates semi-automatically with manual closure—offering maximum flexibility.
A: The solution is a vertical rotary cartoner with quick-change tooling, enabling seamless transitions between carton sizes in 30 minutes. This makes it ideal for cartoning machines used in high-mix, low-volume operations. Its modular design allows the machine to switch between fully automated and semi-automated workflows, depending on the size of the carton.
A: Accuracy is built into every stage of the automatic cartoning process. The system integrates sensor-driven part counting, real-time carton verification, and a post-fill checkweigher with a reject system. This ensures each carton meets precise weight and count requirements—essential for consumer product packaging machines targeting retail compliance and consistency.
A: As a turnkey integrated packaging solution, the system minimizes engineering hours while maximizing return on investment. By automating formerly manual tasks, it reduces labor costs, shortens production cycles, and improves package consistency. This leads to greater operational efficiency, enhanced product presentation, and increased scalability for growing business.
A: Modern cartoning machines, like this custom vertical rotary cartoner, are highly adaptable and can be tailored for use across multiple industries including consumer goods, pharmaceuticals, automotive components, and more. With features like quick-change tooling, precise part counting, and label application, these automated packaging machines support diverse product shapes, sizes, and compliance needs. Whether it’s retail display packaging or storage/warehouse packaging, automatic cartoning provides a scalable, consistent solution for any sector seeking to boost efficiency and presentation quality.
