Automating Pet Food Case Packing: More Formats, Less Manual Handling
Different tub sizes. Different pack quantities. One case packing system designed around the production line.
For pet food manufacturers, filling and sealing the product is only part of the job. Those tubs still need to be grouped, packed and secured into cases ready for distribution.
When product sizes and pack configurations vary, that final stage can become increasingly demanding. Manual packing adds repetitive handling, while equipment with limited flexibility can make changing formats more difficult.
For this pet food application, Fibre King designed a WAP15 Wraparound Case Packer solution to handle 400g and 800g tubs across a range of shipper configurations—bringing product collation, loading, case forming and sealing into one automated process.
Is Case Packing Becoming the Constraint on Your Line?
Increasing production upstream only helps if the packing process can keep pace.
For manufacturers reviewing their end-of-line operations, the questions are often practical:
How much repetitive handling is involved in packing each case?
Can one machine accommodate different tub sizes and pack quantities?
How consistently are products grouped and cases sealed?
How will the equipment fit into the existing production layout?
What is involved when operators need to change formats?
The right automation solution starts with these requirements. Machine selection should follow a clear understanding of the products, pack configurations and production environment.
The Brief: Two Tub Sizes and Multiple Pack Formats
This project called for automated case packing of pet food tubs from an existing production line.
The specified requirements included:
400g and 800g tubs
8, 12 and 16-pack shipper configurations
Single and double-layer product collation
Automatic wraparound case forming and glue sealing
The challenge was to bring those requirements together in a system suited to the available space and the
way products arrive from upstream equipment.
Fibre King’s proposed solution centred on the WAP15 Wraparound Case Packer, with product handling and collation configured for the application.
How the Wraparound Case Packing Process Works
Rather than loading products into a previously erected box, a wraparound case packer forms a corrugated case around a collated group of products.
For this application, the process brings together four key stages.
1. Tubs arrive and are organised into lanes
Filled and closed tubs enter the machine on a single-lane conveyor. A servo-controlled divertor directs them into three or four lanes, according to the required packing format.
This establishes the arrangement needed for the next stage.
2. Products are collated into the required configuration
The machine separates the tubs into groups. Depending on the selected format, it prepares a single layer or stacks the products into two layers before loading.
This is where the product handling design matters: the machine must manage both the tub dimensions and their arrangement within the finished case.
3. The product group is loaded into a case blank
The collated tubs transfer into a waiting corrugated blank. The machine forms the case around the products as they move through the packing sequence.
4. The case is glue-sealed and discharged
Adhesive is applied, the flaps are closed and compression plates hold the case during sealing. The completed shipper then exits the machine.
Watch the video to see the WAP15 packing pet food tubs.
What This Approach Is Designed to Deliver
Automating these steps can help manufacturers reduce repetitive manual packing while improving consistency across the process.
For this project, the system was designed to support:
Less manual handling: automating product grouping, loading and case sealing.
Consistent packing: controlling how tubs are arranged and enclosed within each case.
Format flexibility: accommodating the specified tub sizes and shipper configurations.
Integration with existing production: configuring the infeed and machine layout around the application.
These are practical considerations for any manufacturer assessing automation. The value comes from how well the equipment fits the production task and supports the people operating it.
Engineering Around the Product—and the People Running the Line
A case packer needs to do more than run one format during a demonstration.
Operators need a clear changeover process. Maintenance teams need access and useful diagnostics. Production managers need equipment that works with the rest of the line.
The WAP15 solution includes product selection and diagnostics through the operator interface, adjustable settings for different case formats, and remote access capability to support troubleshooting.
Fibre King brings design, manufacturing, integration, installation, training and ongoing support together—providing continuity from the initial application review through to day-to-day operation.
Could Your Tub Packing Process Work More Efficiently?
If manual packing is becoming harder to resource, or your product range is adding complexity, start with the requirements of your line.
Tell us your tub sizes, case configurations, current packing process and target output. We’ll help you assess a practical automation concept, with an indicative budget and delivery timeframe.
