Secondary packaging rarely follows a standard approach. At BluePrint Automation, we’ve engineered case packing systems that range from high-speed drop packing to complex, multi-axis robotic handling.
Each application brings a different set of challenges, and the right choice depends on more than upfront cost. Floor space, labor availability, long-term flexibility, and the physical characteristics of the product all play a role in selecting the right technology.
Two of the most frequently compared technologies in our lineup are gravity case packers and gantry-style case packers. While both are engineered to provide turnkey secondary packaging, they operate very differently and are best suited for certain products and applications.
We’ll compare both types of case packers in this guide to help customers get a better understanding of how they work and where they thrive. Topics we will cover include:
The gravity case packer is a workhorse. It is designed to top-load flat-packed products into cases with a simple, repeatable motion. By utilizing the natural force of gravity, this machine minimizes the need for complex robotic arms, making it an incredibly efficient choice for certain applications.
On a BPA gravity case packer, the process is streamlined for speed. The product enters the system on a conveyor belt depending on the rate of throughput desired.
Once the product is positioned, the gates rotate at high speed, dropping the row or layer of product directly into the case. To ensure the product settles tightly and stays within the case dimensions, a vibratory conveyor is integrated into the loading station, settling the bags as each layer is added.
Gravity case packers are engineered for free-flowing bags. If you are packing bags of individually quick frozen (IQF) proteins, frozen fruits and vegetables, dry rice, beans, or sugar, a gravity case packer is often the superior choice. These products can handle the drop without damage, and the vibration helps the loose contents settle flat for a clean case seal.
While gravity systems are great for high-speed top loading, gantry-style case packers offer greater flexibility with various products and packaging formats. If your production demands require more than just a flat pack or if you are handling a variety of packaging formats beyond just pillow bags, our gantry case packing systems may be your best option.
The gantry system utilizes a fully servo-driven robot that operates on an overhead bridge (or gantry). This allows for incredibly smooth, precise, and gentle placement of products. Unlike the gravity’s drop, a gantry-style case packer picks and places the product using a specialized end-effector.
Our Gantry series is available in three primary configurations based on your needs:
Depending on your pack pattern, a gantry can work in two ways:
When choosing between these two systems, plant managers often look at the initial capital expenditure. However, the true return on investment (ROI) is found in the daily operational costs.
A major ROI factor that is often overlooked is changeover labor. A gravity system has no changeable parts. Changing from one pack pattern to another is largely an automatic process via the HMI, requiring almost zero time from your maintenance or operation team.
A gantry system, while highly flexible, requires physical change parts (end-effectors, belts, or cassettes) when moving between different SKUs or switching from horizontal to vertical packs. While BPA designs these for quick changeovers, those extra minutes can add up over multiple shifts.
The gravity system, with its simple design, is easy to maintain and inspect. The gantry system has more components, including the servo-driven robot, the specialized end-effectors, and the collation belts.
A gantry case packer will naturally require a more skilled operator and more frequent inspections, but keep in mind we offer aftermarket support and maintenance programs for all of our machines to help maximize their longevity and performance.
For high-volume co-packers, the decision usually comes down to the diversity of your contracts.
Lean toward the Gantry if you are running many different SKUs, various case styles, and changing pack patterns (horizontal today, vertical tomorrow). The gantry’s ability to adapt to future contracts makes it a safer long-term investment for a flexible facility.
Lean toward the Gravity if you have a dedicated line running pillow bags into flat-horizontal patterns. If your product is consistent and your goal is maximum throughput in a tight space, a gravity case packer is the more cost-effective and efficient solution.
At BluePrint Automation, we understand how critical your secondary packaging line is to meeting throughput goals, and we work with you to identify the right solution to achieve them.
When you partner with BPA, we go beyond just looking at speed. We evaluate:
Whether you need the simple, ruggedness of a gravity case packer or the heavy-duty flexibility of a gantry system, BPA is here to run the numbers, perform the tests, and prove the results before a single product is packed. Ready to see which system wins for your specific application? Reach out to our experts today.