Introduction
At a Glance
Budgeting for a side load case packer is highly dependent on your pricing expectations, product formats, SKU-mix, and overall wants and needs. Side load case packers can be intermittent or continuous motion, fast or slow, highly complex or extremely simple. It depends on what you want and what your operation needs.
Account for the following cost drivers when budgeting:
- Product format, predictability, and package quality
- SKU-mix variability
- Infeed orientation or shape
- Product manipulation expectations
- Case/flap format and quality
- Speed and size expectations
- Add-ons and capability expectations
The more you want your machine to do, the bigger, the costlier, and the more complex your side load case packer will be. Evaluate what’s a want, what’s a need, and what’s crossing the line.
Case packers – in this article, side load (also known as horizontal load) case packers – are the middlemen in the line, the culmination of years of engineering efforts, and the machines that put the “pack” in the term “secondary packaging.”
Given their central importance, case packers can also be expensive. But done well, budgeting for a case packer can evade the unnecessary expenses and lead you to a production line that quickly returns the investment. So, now the question is, “How Much Does a Side Load Case Packer Cost?”
In this article, we’ll cover:
- Pricing and functionality in different side load case packer tiers
- The factors that can drive or evade expenses
- Common side load case packer add-ons
- Questions to ask vendors when comparing quotes
What Do I Get with My Side Load Case Packer Budget?
Like any packaging automation, the pricing and functionality of side load case packers varies. Between intermittent and continuous motion, add-ons, and engineering improvements, there are options for just about every budget (from baseline up).
However, we’ve broken up this broad spectrum into 4 general tiers. Our estimates are based on Douglas’ 60+ years of industry experience as well as the input of our subject matter experts. But the exact pricing of your machine will only be found by talking to your vendor and receiving a quote.
Options
Price Range
Throughput
Motion
Baseline
Autopopulated Value (Mobile Only)
$250,000 – $300,000
Autopopulated Value (Mobile Only)
15 – 20 CPM
Autopopulated Value (Mobile Only)
Intermittent Motion
Mid-Range
Autopopulated Value (Mobile Only)
$480,000 – $775,000
Autopopulated Value (Mobile Only)
20 – 30 CPM (standard); 30 – 50 CPM (with add-ons)
Autopopulated Value (Mobile Only)
Intermittent Motion
Mid-Range 2.0
Autopopulated Value (Mobile Only)
$1.0M – $1.2M
Autopopulated Value (Mobile Only)
50 – 60 CPM
Autopopulated Value (Mobile Only)
Hybrid/Dual-Indexing
High-Range
Autopopulated Value (Mobile Only)
$1.2M – $1.8M
Autopopulated Value (Mobile Only)
70 – 120 CPM
Autopopulated Value (Mobile Only)
Continuous Motion
CPM = Cases per minute
1
Baseline
A baseline side load case packer will be an intermittent-motion (IM) machine (meaning it will move by stopping and starting between stations). And it will most likely include a tamp chain coupled with either a load deck or load chain.
For more information on tamp and load infeeds – the different types and their functions – take a look at our article: “The 4 Types of Tamp and Load Infeeds Explained.”
This baseline machine will suit rectangular or round, rigid product, as unusual product formats require additional containment measures. The machine handles basic product grouping, while other product manipulations are done separately. You could also explore stacker options if you are willing to go beyond the baseline price.
Price Range: $250,000 – $300,000
Throughput: 15 – 20 CPM
2
Mid-Range
A mid-range side load case packer will still be intermittent in motion, but will feature add-ons that go beyond the functionality of the baseline case packer. The tamp chain, load deck/load chain functions will still be the heart of the case packing, but the machine may also have infeed product manipulation, product variability capabilities, pre-installation product testing, etc.
Price Range: $480,000 – $775,000
Throughput: 20 – 30 CPM (standard); certain machines with add-ons may run 30 – 50 CPM
3
Mid-Range 2.0 (Hybrid Option)
In certain scenarios, you may find a side load case packer that falls somewhere between IM and continuous motion (CM). It would be a sort of hybrid, dual-indexing machine. The main benefit is the addition of space, while not having to keep up with full CM.
Price Range: $1.0M – $1.2M
Throughput: 50 – 60 CPM
4
High-Range
A high-range side load case packer is distinctly different in that it’s a CM system. The machine does all of the case packing functions without stopping. This naturally increases speed capabilities, but also requires a certain level of operation to be practical. To increase productivity beyond this level, operations may seek out add-ons to purchase and integrate into their machine.
Price Range: $1.2M – $1.8M
Throughput: 70 – 120 CPM
Note: Increasing speed and machine capacity beyond what we have listed in the “high-range” is possible, but requires additional cost, and a vendor who can accommodate your wishes.
At Douglas, our specialty is creating high-quality, customized solutions. If you’re interested in further capabilities, explore what Douglas has to offer.
The Big Cost Drivers: Products and Wants
Price ranges and automation tiers are only as handy as your understanding allows. So, it’s important that you know the factors that impact cost.
Generally, anything that varies from standard format will drive up machine cost. Sometimes this is necessary given your SKU-mix, but other times it can be helped by talking to your vendor and evaluating where changes might be made.
Here are some of the big cost drivers:
Product Characteristics
Machines are generally built to suit a standard product in size, weight, and format. So certain deviations in your SKU-mix may need additional components to accommodate. Here are some especially influential factors:
- Predictability – Firm, rigid product will be easier to pack; tapered, tippy, or bouncy product will prove more difficult, and may require additional handling components.
- Wash Package – Depending on your product, you may need additional measures to aid in protection and sanitation.
- Product Weight – Especially heavy products will require a more robust machine, with additional components.
- Size Inconsistencies – If you are running many different product variations on the same machine, more accommodations may be required for proper machine function.
- Product Shape – Square or round products are simple to pack, while products with asymmetric shapes can be more difficult (e.g. gable-top cartons or oval bottles).
- Material Quality – If your primary packaging is prone to warping, bending, puncturing, or breaking, consider different packaging, or add machine components.
- Product Distribution – Product that shifts or bulges in different parts of the primary packaging will cause distribution and shape changes that require accommodation.
SKU Mix and Flexibility
Increasing machine flexibility to meet SKU mix variability will always add cost. Every machine is built to meet a specific range of case sizes. Those that exceed this range will need additional machine components and possibly change parts.
Besides cost, this may make changeovers more complex, and introduce the desire for auto adjust points, which lessen the changeover load through machine programming (but add on-to cost). Another factor to consider with SKU mix is different or multiple product manipulations (see next section). This multiplies the cost and complexity with each SKU the machine needs to accommodate.
Infeed and Manipulations
It matters greatly how the product comes into the machine (e.g. lanes, single-file, etc.). Accommodations will need to be added to the machine if the product is coming in from an orientation that is not considered “standard” – for example, if the product is being packed side-forward, or if it is laying down rather than standing up. These are things you should specify with your vendor early.
To learn more about product orientation, take a look at our article, “What Is Product Orientation in Secondary Packaging and Why Does It Matter?”
Manipulations are arguably the greatest pricing factor. Anything you have to do to reorientate or “manipulate” the product, adds cost and complexity (and ultimately affects speed). This could be rotating, orientating, tipping, etc., either before or after packing and sealing. To be most cost-effective, you’ll want to have your infeed product in the exact orientation and format you want it packed in.
Pro Tip
Ask yourself, “What’s the max rate I can output from my filler?” Then consider where that rate will be in 3-5 years. This is a great way to gauge for your speed needs, and to evaluate whether an additional speed component is a practical decision right now.
Case/Flap Styles
As we mentioned earlier, variability in product or case size on one machine will add complexity and cost (scaled to the extent of the range). It’s the same with mixing different case types. Anything that changes size, weight, distribution, etc. will need accommodation.
- Case Formats – Different case formats require distinct components to run through the machine. Wrap-around, tray, shrink wrap, or any other format, will have its own cost and complexity drivers.
- Flap Formats – The length and format of your case flaps may also contribute to cost and complexity in your machine. The scale of flap cost-effects will vary from vendor-to-vendor.
- Case Tightness – A case that is oversized or undersized compared to the product, needs added components, or will present problems when closing and sealing the case.
- Case Quality – Bowed or warped corrugate creates difficulty. In some situations, it may be the better choice to upgrade for the sake of cost-effectiveness and productivity.
What’s the “Perfect Case”?
The “perfect case” is the case that will run through your machine with no added components. This will vary depending on vendor (and machine). If your case ends up being an outlier, you may see cost and complexity increases through added components.
Will My Facility Cause Extra Costs?
If you are limited in space, the constraints of your facility may be a factor. Design changes can be made to meet floorplan requirements, but will increase engineering time and, likely, new cost items.
Lane dividing is a feature buyers often request, but it does add length to infeed, and cost if you need a high-speed lane divider to meet throughput demands. SKU-mix, range, and throughput needs may add length to the machine. Generally, the faster the machine goes, the bigger it’s going to be. And a bigger machine means more components to pay for.
What If I Am Interested in More?
Once you get into the higher automation tiers, you may be interested in add-ons. Add-ons are options that you can have integrated into your machine to expand your machine’s features. They’re a tradeoff: higher price for more capabilities and improved productivity. Here are some common choices:
- Auto Adjust Changepoints – Automate some aspects of changeovers through additional machine programming. This lessens the burden of changeover, making it more repeatable and reliable for the life of the machine.
- Guarding Options – Material or spatial guarding to accommodate product or supplier requirements. Some examples include stainless steel grids, expanded mesh, acrylic styles, guard door handles, guard door switches, dust cap roofing, etc.
- Controls and Electrical Adders – Vendor or third party-specific controls options or electrical hookups. At Douglas, we often see GuidePoint® or RFID additions.
- Cameras and Coders – Integrating cameras or coders for case, code, and product verification. They cut out additional steps in production and can manage some quality control through case reject.
Comparing Quotes? Ask About These Value-Adders
Let’s say you’ve received quotes from two competitors for similar machines, but they vary greatly in price. Rather than immediately signing with the less expensive option, ask your vendors if their machines and/or contracts include these value-adding factors:
Machine Construction Adders
- Machine Durability
- Accessibility to Core Areas – for maintenance ease
- Servo Flight Adjust – technically an adder, but may be included in base price
- Automated Features to Assist – parameterization, SCARA arms, HMI functionality, etc.
- Corrugate Tolerance and Variability Allowance
Changeover Adders
- Changeover Ease – without auto adjust add-on
- Standard vs. Additional Auto Adjust
- Adjustment Simplicity
Vendor Relationship Adders
- Quality of Partner Relationship
- Level of Support and Service
While there may be limits to how much you’re willing to pay, you also want to buy the better contract. Sometimes paying more upfront is worth it once you consider all of the value-adding features that are included in the quote.
Make the Informed Decision and Work with the Right People
Budgeting for a side load case packer can be overwhelming. Beyond general tiers, there are specific case and packing options, weight and SKU variations, facility constraints, add-on features, and numerous vendors. But now you have the know-how to make informed decisions about what to agree to, what questions to ask, and what changes to make.
Perhaps the most informed decision you can make at this step is to find a good partner. Build a trusted relationship with a good vendor – they’ll not only be your guide through the weeds of side load case packer options, but they’ll also be your support throughout the life of your machine.
Still Feeling Overwhelmed?
Schedule a discovery call today. Speak with one of our specialists to learn more about what Douglas offers, and evaluate what side load case packer is right for your budget and operation.
