If you’re new to sourcing end-of-line packaging equipment, you might wonder: what exactly goes into building a complete system? And how do you know what’s right for your line?
Jay Bachman, President of Wayne Automation, has the answers. With decades in the business of designing and manufacturing automated packaging equipment, Jay has seen it all—from early-stage production line setups to full-scale upgrades for Fortune 500 manufacturers.
Jay walks us through the five essential components of an end-of-line system and shares expert advice on how to evaluate your options like a seasoned engineer.
What’s the Purpose of End-of-Line Packaging Equipment?
At its core, end-of-line packaging equipment prepares your product for shipment, protection, and even display. Whether you’re packing beer bottles or cleaning supplies, your EOL system must reliably handle the product, protect it during transit, and make sure it gets to the shelf looking perfect for the customer.
According to Jay, the main goals are:
- Protection – so your product survives warehousing and logistics
- Presentation – for retail visibility and marketing
- Efficiency – so your packaging process doesn’t become a bottleneck
To achieve that, you’ll typically work with five categories of industrial packaging and equipment—each with its own function, challenges, and selection criteria.
1. Forming: Building the Outer Structure
According to Jay, “When it comes to the forming aspect of end-of-line packaging, number one is, what kind of package do you want your product to be in?”
Forming is where you build the outer structure of your package—whether that’s a box, tray, or wraparound case. This first step sets the stage for everything else in your packaging line.
Common equipment includes:
- Case Erectors – form pre-glued blanks into ready-to-pack cases.
- Tray Formers – build low-wall containers often used in retail displays.
- Wraparound Case Formers – fold and seal a flat blank around the product.
Key considerations:
- Desired packaging format (RSC case, tray, wraparound)
- Production speed and run size
- Frequency of changeovers
- Future flexibility for different package types
2. Inserting: Internal Dividers for Strength and Protection
Next is inserting—a step often overlooked until bottles clank together or boxes collapse.
This is where partition inserters or inner pack dividers come in. They might look simple, but the impact is significant:
- Protect fragile items like glass bottles
- Add stacking strength to keep boxes from crushing
- Stabilize multi-product packs for transit
What to evaluate:
- Are you prioritizing product protection, structural strength, or both?
- What styles of partitions do you need, now and in the future (e.g., 6-pack now, but might eventually need 12-pack)?
- How many variations will you run on the same machine?
3. Packing: Placing the Product Into the Case
Now it’s time to load the goods. Packing equipment can vary widely depending on the product:
- Drop Packers: High speed and common for bottles and cans.
- Pick-and-Place Machines: Ideal for delicate or irregular products. Highly adaptable for varying products.
Here, your decision hinges on:
- Product type and fragility
- Desired speed
- Orientation requirements (e.g., labels forward, upright positioning)
Wayne Automation offers several packing equipment options to meet these varied needs, all designed to integrate smoothly with upstream and downstream equipment.
4. Inspecting: Quality Checks Before Sealing
Before sealing the case, it’s essential to inspect it. Jay emphasizes, “When it comes to inspection, it’s making sure that the products are there, they’re present, they’re undamaged, and that the packaging set up as was designed and intended, ensuring that that product gets to its end point of use unblemished and presented as you intend.”
Inspection tools may include:
- Checkweighers – to verify product counts or detect missing items
- Vision Systems – to ensure proper placement and spot defects
- Laser Scanners – for advanced shape or alignment verification
Why it matters:
- Prevents costly rework or rejected pallets
- Ensures the packaging matches your design intent
- Supports traceability and QA documentation
5. Sealing: Securing the Finished Case
Sealing finalizes the package and prepares it for shipping or palletization. Most systems use:
- Hot Melt Glue – for fast, durable seals on high-speed lines
- Tape Sealers – ideal for RSC cases, quick changeovers, and anti-tamper applications
- Custom Sealing Solutions – for oversized or specialty packaging needs
Selection criteria include:
- Desired throughput
- Packaging style (single flap, all flaps meet, tablock, nuna flaps, nuna tabs)
- Compatibility with forming and inserting machines
What Should Engineers Look for When Choosing Equipment?
Jay puts it this way, “The end-of-line packaging solution you put in place will be installed into a plant, and it will be there for many, many years to come.” Consider the following when choosing your equipment:
- Design for the future. Build flexibility into your line so it can adapt to new package sizes, SKUs, or speeds.
- Match speeds and capabilities. A mismatch between your case erector and packer will cause delays.
- Work with a partner, not just a vendor. Leading packaging machine suppliers help you design, integrate, and evolve your system, rather than simply dropping off a machine.
Wayne Automation helps clients design full systems, not just one-off solutions. With decades of experience and a broad product line, we’ve become a reliable choice among packaging machine suppliers in the U.S.
Ready to Design Your End-of-Line System?
Your end-of-line packaging equipment will be in place for years—possibly decades. Get it right the first time with equipment that works in sync and a team that understands what engineers need.
Contact Wayne Automation today to start designing your system for performance, flexibility, and long-term success.
