How To Pack Multi-tea Bags into A Carton Showbox by Machine Automatically

Automating the process of inserting multiple tea bags into a carton show box is a classic packaging automation challenge. It involves several integrated systems working in harmony.

Here is a detailed breakdown of how this can be achieved by a machine, from loose tea bags to a sealed, finished carton.

The Core Stages of the Automated Process

The system can be broken down into five main stages:

1. Tea Bag Feeding and Orientation

2. Grouping and Counting

3. Carton Erection and Placement

4. Precise Insertion

5. Closing and Sealing

1. Tea Bag Feeding and Orientation

This is the first and often most critical step. Tea bags arrive from the manufacturing process in a bulk, disorganized state.

• Solution: A sachet sorting and counting machine.

• sachets sorting counting machine including functions, hopper chute, lift conveyor, hoist unit, sensor, bag pressing device, conveyor roller, brush with motor, control panel, count, finish product conveyor, machines are controlled by PLC system.

• Belt Feeder with Vision System: For very delicate or irregularly shaped tea bags, a vision-guided robotic pick-and-place system might be used. A vision camera identifies the position and orientation of each tea bag on a conveyor, and a robot (delta robot is ideal for high speed) picks them up and places them in the correct orientation onto the next conveyor.

• Pouch counting and sorting device using motion controller, suitable for production line connection of multi-row sachet packing machine.
  

2. Grouping and Counting

Once oriented, the tea bags need to be grouped into the exact quantity for one box (e.g., 5, 15, or 30).

Reference case for multi-bag sorting and packaging--->>>

Reference case for Multi Sachets Cartoning Machine Line--->>>

• Solution: A Combinatorial or Batch Counting System.

• The oriented tea bags are fed in a single file onto a conveyor.

• Pocketed Conveyor: A conveyor with pockets or lanes is often used. Each pocket holds one tea bag. As the conveyor indexes (moves in precise steps), a sensor (e.g., photoelectric) counts the tea bags.

• Group Formation: After the correct count is reached, a gate mechanism or a sweep arm gently pushes the group of tea bags into a "nest" or a "bucket" that holds them tightly together as a single, neat bundle. This is crucial for clean insertion.

3. Carton Erection and Placement

Empty, flat cartons (knocked-down flat blanks) are loaded into a magazine on the machine.

• Solution: A Carton Erector.

• A suction cup (or a set of cups) picks a single flat carton from the magazine.

• It opens the carton by moving the suction cups in a specific pattern to form the rectangular shape.

• The bottom flaps are then folded and often pre-sealed (hot melt glue or tuck-in flaps) to create a stable, open-top box.

• This erected carton is then placed onto a conveyor carrier or a mandrel that will transport it through the insertion and closing stations.

4. Precise Insertion

This is the stage where the bundle of tea bags is placed into the waiting carton.

• Solution 1: Pusher Mechanism (Most Common for Rigid Bundles)

• The nest holding the tea bag bundle is positioned directly above the open carton.

• A pneumatic or servo-driven pusher plate descends and pushes the bundle neatly down into the carton. The nest retracts as the pusher moves, ensuring a controlled transfer.

• Solution 2: Robotic Pick-and-Place (For Flexibility or Delicate Products)

• A robot equipped with a custom end-effector picks up the entire grouped bundle. The end-effector could use gentle friction grips or suction cups designed to not damage the tea bag paper.

• The robot then moves and precisely places the bundle into the carton. This method is gentler and better for complex patterns or if the tea bags are not bundled tightly.

5. Closing and Sealing

Once filled, the carton moves to the closing station.

• Solution: Flap Folding and Sealing.

• The top flaps of the carton are folded closed in a specific sequence.

• For Glue Sealing: Nozzles apply a precise dot or line of hot melt adhesive to the flaps before they are folded and pressed shut for a few seconds to set.

• For Tuck-In Flaps: Mechanical fingers simply tuck the flaps into each other for a glue-less closure.

• The sealed carton is then discharged onto a conveyor to be sent for case packing and palletizing.

System Integration and Control

The entire machine is controlled by a Programmable Logic Controller (PLC) and a Human-Machine Interface (HMI) touchscreen. The PLC coordinates the timing of all the motors, sensors, pneumatics, and robots. Sensors throughout the machine verify each step (e.g., "carton present," "tea bag count correct," "glue applied") to ensure quality and stop the machine if a fault is detected.

Machine Types

• Intermittent Motion Machine: The conveyor stops at each station (erection, filling, closing). This is simpler and suitable for medium speeds.

• Continuous Motion Machine: The conveyor moves continuously at a constant speed, and all operations are performed "on-the-fly." This is more complex but allows for much higher production speeds.

Key Considerations for a Successful Machine

• Tea Bag Variability: The machine must handle different sizes, shapes (round, pyramidal), and materials without tearing or damaging the product.

• Hygiene: Materials in contact with the tea bags should be food-grade and easy to clean (e.g., stainless steel, approved plastics).

• Changeover: For producing different tea types or counts, the machine should allow for quick and easy changeover of parts like the bowl feeder tooling, grouping nests, and carton magazines.

• Speed (Units Per Minute): The required production speed is a primary driver of the machine's design and cost.

MiGrand's program engineers can design packaging programs that fully meet your requirements according to your specific requirements.