How We Pack Stand-Up Pouches Upright in Shipping Cases

On many pouch packaging lines, operators still open and form shipping cases by hand, load the pouches upright, and seal the filled cases. Some plants use a case sealer for the final step. We can automate all three steps with a case erector, a pouch case packer, and an automatic case sealer.

A stand-up pouch can sit squarely on a shelf and still tip when it meets the edge of a shipping case. At Smart Weigh, we arrange and count the sealed pouches, form a complete group, and guide that group into the case with the pouch bases down. The transfer keeps the pouches upright until they are seated in the case.

Five pouches per case on an existing packing line

A food manufacturer in Russia already had a multihead weigher and a pouch packing machine in production. We supplied the case-packing section to run downstream of that equipment.

We configured the system to count five doypacks per case and keep them standing during loading. The system ran at approximately 6–7 cases per minute, equivalent to 30–35 pouches loaded per minute for this format.

What happens between the pouch machine and the case

Arrange the sealed pouches for counting. The arranging section brings the finished pouches into a consistent position. If the pouches overlap coming off the bagger, the infeed needs to space them out so the machine can count each one.

Build the case load. The machine counts out the required quantity and gathers the pouches in the arrangement specified for the case. We agree on the row pattern and, where it matters, which way the front panels should face. A photo of a correctly packed case is often the easiest way to show the arrangement.

Guide the group into the case. A mechanical transfer moves the assembled group into the open case while keeping the pouches standing. The case opening has to line up with the group so the bags can enter without catching on the edge. This type of loading works well when the filled pouches can be presented consistently and the case layout repeats from cycle to cycle.

Why we ask for filled pouches and an actual shipping case

Two products can use the same size pouch and still need different loading setups. The fill can make one pouch bulge in the middle while another sits wider at the base. Those differences affect how much space a group of pouches needs as it enters the case.

We check the height, width and thickness of the filled pouch against the usable inside dimensions of the case. Too little clearance and a pouch can snag as the group goes in. Too much room and the bags can lean after the transfer releases them. We also check that the case flaps can close without pressing on the tops of the pouches.

If you run several formats, send filled samples and a matching case for each one. During a trial, check the pouch count, the standing position after the case moves away from the loading station, and the condition of the seals and film. That also gives you a chance to see which guides or settings need to change between formats.

How we connect to an existing pouch packing line

We start at the point where the sealed pouches leave your machine. We check the conveyor height, direction of travel and available space on your line layout. A short production video shows how the pouches leave the bagger and how their spacing changes as the line runs. We also establish how open cases will reach the loader and where filled cases go next.

We size the case packer using the output of sealed pouches that reach it. For example, if your line supplies 45 pouches per minute and you pack five per case, the loader needs to average nine cases per minute to keep pace. Short bursts and interruptions help determine whether the line needs temporary conveyor storage, known as accumulation.

We also work through what happens if the case supply stops halfway through a count. We define when to pause the pouch feed and what to do with the pouches already counted when production resumes. If you need automatic case forming and sealing, we can include a case erector and a sealer in the scope of the end-of-line packaging system.

What to send us for a case packing review

Start with a filled pouch, the inside dimensions of your shipping case, and a photo or sketch of how you want the bags arranged. Include the number of pouches per case, your usual pouch output, and a short video of the current discharge. With those details, we can identify where the case-packing section would connect and what to test with your samples.

Send your pouch and case details to Smart Weigh.