Automatic Counting and Cartoning of Multi-Format Sticks

Our pharmaceutical client in Sicily was running a high-speed 10-lane stick machine capable of reaching 500 powder sticks per minute.
While production fully met its targets, the end of line was a real bottleneck to performance.

The sticks were packed into cartons manually, which resulted in:

• insufficient speed relative to the machine’s output

• counting errors

• several operators tied up

• a constant risk of line saturation

The challenge was to automate without compromising production speed.

Demanding technical constraints

The project presented several industrial challenges:

• very lightweight powder sticks (3 g)

• very high speed to accommodate

• multiple stick formats (90 mm and 120 mm)

• variable counts depending on the carton (14, 15, 20, 30…)

The solution had to be fast, reliable and flexible all at once.

A complete conveying, counting and cartoning line

We designed and integrated an automated system directly at the stick machine outfeed.

The system works as follows:

• orienting the sticks as soon as they leave the cutting stage

• conveying and unit separation of the products

• automatic high-speed counting

• transferring batches to the cartoning machine

• inserting the sticks and the pre-folded leaflet

• automatic carton closing

What makes the system unique is its ability to handle different stick counts per carton without complex changes to the line.

Results Achieved

Going into production achieved:

• full speed maintained

• over 200,000 sticks cartoned in a single day

• elimination of 4 operator positions dedicated to manual loading

• maximum counting reliability

• improved working comfort

Operators now perform a supervisory role rather than manual handling.