Case Forming Solutions by Pearson Packaging

Reliable, High-Performance Automation for Efficient Box Forming

In today's highly competitive manufacturing and distribution landscape, automated case forming is an important component for businesses looking to reduce labor costs, improve packaging quality, and enhance operational efficiency of their end-of-line packaging process. Manual case erecting and forming processes are time-consuming, slow and sometimes not even practical, for example when forming bliss boxes.

With over 70 years of experience in Box Forming Automation, Pearson Packaging Systems delivers industry-leading Case Erectors and Bliss Formers backed by a robust support system of on-call and ready-to deploy service technicians, remote troubleshooting and service capabilities, and parts and aftermarket assistance to ensure your packaging lines run optimally. Our solutions are engineered for 24/7 operation, fast changeovers, and maximum reliability in a small footprint, ensuring high-quality packaging with minimal waste.

This overview explores the key benefits of Pearson’s automated case and bliss forming equipment, highlighting how our time-tested solutions help high-volume manufacturers and distributors optimize their secondary packaging processes.

How Automated Case & Bliss Box Formers Reduce Operational Costs

1. Labor Cost Reduction with Automated Case Forming

The increasing cost of recruiting, training, and retaining workers especially for highly repetitive and mundane tasks such as case forming propelled a surge in automating every aspect of the secondary packaging process. High labor turnover combined with a shortage of workers willing to perform repetitive, physically demanding tasks is one of the most significant drivers our customers invest in a Case Erector.

With Pearson Packaging's Case Erectors and Bliss Formers, companies can greatly reduce dependency on human labor, allowing employees to focus on higher-value tasks. Equipped with a highly intuitive and engaging interface, even new operators can quickly run Pearson machines independently with minimal training, making your operations smoother and more efficient.

2. Increased Output with Minimal Downtime

Although Pearson Packaging offers a wide range of speeds for our Case Formers and Bliss Formers, many customers are looking to increase their overall line throughput. For that, automation solutions provide continuous operation and high-speed performance. Box forming automation solutions from Pearson Packaging Systems offer consistently high output rates, capable of handling up to 50 cases per minute for case erectors and 40 boxes per minute for bliss formers.

3. Consistently High-Quality Output & Reduced Waste

Corrugate is a huge cost center for manufacturers, but waste increases operational costs even more dramatically. Improperly formed cases can lead to poor pallet stacking, increased product damage, and inefficient use of packaging materials. Pearson's Case Erectors and Bliss Formers have stood the test of time in even the most demanding of environments ensuring perfectly square cases for secure stacking and transportation and accommodating corrugate variances, maintaining high-quality output even when material properties fluctuate.

Maximizing Floor Space: Compact & Space-Saving Case Forming Equipment

In manufacturing environments, floor space is a premium resource. Pearson’s Case Formers and Box Formers take that into consideration by minimizing footprint without sacrificing performance. With features such as sliding doors or gravity-fed magazines, our case and bliss formers fit into tight production areas without major layout changes. They easily integrate into existing packaging lines without requiring extensive modifications and optimize available manufacturing real estate, leaving room for other essential operations.

Reliability & Durability: Investing in Robust Case Forming Equipment

1. 24/7 Operation with Minimal Maintenance

Automating a packaging line is a long-term investment. Manufacturers naturally look for robust, reliable, and long-lasting equipment. Pearson’s Case Erectors and Bliss Formers are designed for 24/7, high-volume operations with a heavy-duty construction. Stainless steel and low-pressure washdown construction options ensure that your Pearson automation equipment performs at its best even in high-humidity or salty environments such as near coastal areas.

2. The Importance of Square Cases

A well-formed, square case is essential for:

• Secure seals once the box is being closed with tape or glue as skewed flaps prevent proper tape adhesion
• Strong pallets, which reduces shifting and potential damage during transport
• Optimized warehouse storage, leading to cost savings.
• Enhanced product protection, preventing damage and returns.

Pearson’s Case Formers guarantee consistently square cases by using synchronized dual chain drives to transfer the box through the erector, which maintains case squareness during the closing and sealing process, effectively reducing waste and improving packaging line efficiency. Bliss Formers use a mandrel, that engages the end panels and drives them into a die cavity for consistent glue compression and guaranteed case squareness.

3. Tolerance to Corrugate Variances

Variations in corrugate quality, which are very common, can cause issues with case forming and sealing. Pearson’s case erectors use a dual opposed erecting mechanism and positive case selection and transfer, which increases the machines tolerance of knock-down case variances. These characteristics reduce jams, misfeeds, and errors, to maintain high-quality case output despite fluctuations in materials.

4. Reliable Support for the Life of Your Pearson Equipment

For most of our customers, every minute counts. 10 minutes of production loss can easily cost tens of thousands of dollars, which is why many take advantage of Pearson’s remote support to diagnose, troubleshoot and proactively order parts. In many instances this avoids having to wait for a technician to travel out and if that becomes necessary, remote diagnosis ensures that parts can be ordered proactively so that they are on-site when our technician arrives.

Since many of our customers run 24/7 operations, having access to Pearson’s 24/7 live service support is critically important to them. We are also able to deploy technicians within 24hrs for in-field emergencies, offer aftermarket modifications, retools and rebuilds, and convenient replacement parts ordering online or through our dedicated team.

Operational Flexibility: Handling Multiple SKUs with Quick Changeovers

Modern manufacturing requires adaptability. Pearson’s Case Erectors and Box Formers are designed for high SKU variability, ensuring that businesses can quickly switch between different production runs on the same line.

Our machines accommodate a wide range of box styles and sizes and changeover is fast, tool-less and simple to accomplish. With an uncluttered design, intuitive navigation, and interactive guides, the HMI acts as a personal assistant to operators of all skill levels.

For operations running a multitude of SKUs at any given time, Pearson’s Random Robotic Case Erector is a great choice to reliably form up to six case sizes in a single cell.

With high-speed performance and minimal changeover time, Pearson’s Case Forming solutions offer unparalleled flexibility highly appreciated in food & beverage, household and industrial chemicals, personal care, distribution and e-commerce industries.

User-Friendly Automation: Simplifying Operations & Training

Pearson’s Box Formers are designed with ease of use in mind. Operators who can work independently free up maintenance resources and keep production lines running smoothly. Yet, high turnover, language barriers, and skill gaps create challenges for operations teams striving to meet their production goals.

To ease this burden and ensure seamless performance, we've long invested into a human-machine interface (HMI) that considers the challenges of the user. Following the principles of Person’s User-Centric Design philosophy, the HMI offers a streamlined design, intuitive navigation, interactive guides, live sensor maps, and advanced maintenance tools. It has effectively morphed into an operator’s personal assistant, helping to:

• Reduce operator and technician training time
• Speed up changeovers and fault recovery
• Promote machine maintenance and extend equipment life

The Difference Between a Case and a Bliss Box – and Why It Matters

Both pieces of equipment form boxes intended to be used to ship your products to the retailer or end-customer. Case erectors form knockdown corrugate boards by opening them, folding the bottom flaps and sealing them, creating boxes such as Regular-Slotted Containers (RSC) just like your typical moving box, Half-Slotted Containers (HSC) that are open at the top or Center-Slotted Containers (CSSC) also sometimes referred to as All-Flaps-Meet.

Bliss Formers on the other hand, automatically form sturdy boxes, comprised of body and side panels that are sealed together with hot-melt glue to create a strong and durable container. Selecting between the two case formats depends on the need for stacking strength, retail-display readiness and the characteristics of the product inside.

Bliss boxes are often favored for heavy products like bottles of laundry detergent, industrial-size bags of sauces, or syrups. They also protect sensitive goods such as produce during transport and storage.

Maximize Efficiency with Pearson’s Case Forming Automation

Pearson Packaging Systems has been a trusted leader in case and bliss forming automation for over seven decades. Our high-speed, reliable, and user-friendly Case Erectors and Bliss Formers have helped thousands of businesses:

• Reduce operational costs & labor dependency
• Increase packaging speed & efficiency
• Ensure high-quality, square cases for durable seals and strong pallet stacks
• Adapt to multiple SKUs & rapid format changes

Looking for the best Case Former or Bliss Former for your production line?
Contact Pearson Packaging today to learn more about our Box Forming Automation solutions!