by N. S.
The ACL control is synchronized with the production cycle: the carton flow is constant, micro-stops are reduced, and packaging continuity improves. The ACL operates safely, communicates with line controls, and eliminates repetitive, low-value tasks for the operator.
“Automatic carton loading can be integrated on new machines simplifying layout, safety, and training from the commissioning stage, or implemented as a retrofit that can also be added to existing lines,” introduces the topic Cristian Sala, Sales Executive Manager at Cama.
“On lines where carton loading is still partially manual, the ACL removes repetitive and strenuous tasks, frees up the operator’s time for higher-value activities, and reduces damage related to manual handling. The result is more stable productivity, fewer micro-stops, and a continuous flow of cartons for the machine’s packaging process.”
How the ACL was developed, its objectives, and integration on existing lines
“Automatic Carton Loading was created based on direct customer input: they asked to automate material restocking and eliminate repetitive, high-risk tasks for operators. In many installations, manual loading required lifting heavy bundles of paper and cartons to feed magazines positioned even above 1.5 m in height, an activity that increased fatigue, variability, injuries, and the risk of errors. The ACL identifies the die-cut blank, picks it from the pallet, and inserts it into the magazine in sync with the machine cycle. This means lower risk for people, greater production stability, and consistent quality.” ACL has thus made it possible to eliminate manual replenishment and stabilize the packer’s cadence, with an immediate benefit to operational continuity.
Why can the feeding of die-cut cartons be a critical step?
Along the logistics chain, die-cut carton blanks can change their properties due to transport or storage; the board may warp and lose flatness, become stiffer, or soften. “Humidity variations alter surface characteristics and stiffness, affecting the grip of the suction cups and the separation of individual sheets during handling. In these conditions, the pick-up system has to deal with sheets that may be creased, misaligned, and stacks of board that are not fully suitable for good machinability,” continues Sala. “These issues can have different origins, but in all cases they translate into unstable magazine loading that forces constant intervention on the carton supply to the packaging system, starting with re-aligning the carton stacks while the machine stands. The bottleneck therefore depends less on forming or closing the packs than on the quality of the feeding: if cartons don’t flow regularly, the entire cycle slows down. This is why many companies are integrating solutions dedicated to Automatic Carton Loading (ACL), which stabilize magazine feeding.”
How to integrate ACL on existing lines for carton loading
Automatic Carton Loading (ACL) is a robotic feeding cell that keeps the cartoning machine’s magazine properly and continuously supplied. An articulated robot picks sheets from the strapped bundle on the pallet, safely removes the strapping, recognizes material type and orientation, and inserts the cartons into the magazine with controlled alignment. On existing plants, ACL can be integrated as a retrofit after verifying:
- Space: cell footprint and areas for material infeed;
- Functionality: signal exchange with the machine’s PLC and synchronization with the production cycle:
- Safety: protective guarding and perimeter safety barriers.
“After the presentation at Ipack-Ima 2025, demand has increased,” explains Cristian Sala. “While adoption of ACL on new lines is straightforward, the same system can be integrated as a retrofit, extending the useful life of existing equipment with a fairly quick payback.”
How the ACL works
Automatic Carton Loading identifies the pallet, separates the die-cut blanks, manages the interleaves, and continuously supplies the machine’s carton magazine.
“The device is fully automatic and integrates a vision system. In real time, it can distinguish slight creases from serious damage and decide on rejection when necessary. Every event is tracked and recorded, available for continuous improvement. Operationally, the ACL removes manual carton loading during the packaging cycle because it handles pallet picking, conformity checking, and magazine loading in sync with the cartoner. At its core is the RB003 collaborative robot with modular, sensor-equipped grippers whose grip adapts to the size of each sheet. The ACL’s vision system detects the pallet pattern, orients the stacks, and rejects non-compliant cartons before insertion,” explains Sala.
Vision combines perception and action within the ACL cell by synchronizing camera and robot, so the detected coordinates become safe trajectories for gripping the blanks. The programming software developed specifically by Cama manages both format recipes and synchronization with the machine cycle.
“If parameters exceed the set limits, the logic rejects the individual part, preventing errors and stoppages. Integration takes place via data exchange with the PLC. During picking, the vision system handles misalignments, checks the pick and the blank’s orientation; the head confirms the grip and modulates it according to the material,” continues Sala. “At the factory level, the system can also coordinate flows with Autonomous Mobile Robots (AMRs), receiving pallet-arrival notifications and aligning the pick rate to avoid queues or idle time. Machine downtime is reduced, damage-related scrap falls, and manual handling is eliminated from routine operations. The result is more stable quality, improved ergonomics, and greater production continuity. Day to day, the ACL stabilizes the flow to the cartoner, cuts micro-stops caused by non-uniform pallets, and reduces damage linked to manual handling.”
What are the ACL’s footprint and maintenance requirements
Beyond the highlighted functionalities, the ACL is notably compact. In applications with new machines, the system is integrated directly on the machine’s loading side to reduce floor footprint, keep front and side accesses clear, and simplify operator tasks. The fully electric architecture and low-wear kinematics limit interventions over time; maintenance points are concentrated and accessible without complex disassembly, a characteristic of all Cama machines. Diagnostics include counters, alarms, and reports, ensuring traceability of performed activities. Integrating the ACL with the frame, wiring, HMI (Human-Machine Interface), PLC, CE marking, unified manuals, and a single maintenance plan shortens commissioning times, avoids duplicate documentation, and simplifies spare parts management and checks, yielding a reduced footprint, minimal maintenance, and unified plant management.
Those who have already purchased a machine can integrate ACL later as well
“Yes, Automatic Carton Loading (ACL) is also designed for retrofit. The process starts with a technical site survey and, first of all, a preliminary study. We verify available space, pallet handling routes, the usable height of the carton magazine, and access points for operators and maintenance personnel. In parallel, we define signal exchange with the machine’s PLC and integration with the Human–Machine Interface (HMI) for recipes and diagnostics. Safety functions are adapted to the context,” explains Cristian Sala. “The installation is compact and requires minimal intervention on the existing mechanics; commissioning is carried out with real pallets to validate picking, sheet separation, and insertion. The result is a stable feeding system that reduces non-skilled manual work, cuts micro-stops, and keeps the carton magazine continuously supplied. On new machines, ACL is delivered fully integrated, frame, wiring, HMI/PLC, unified documentation, and certifications. This simplifies commissioning, shortens start-up times, and centralizes maintenance and spare parts. In both cases, the goal is the same: greater continuity, fewer errors, and higher productivity with a system designed to fit the plant, today and tomorrow.”
