How to Change Format Parts on an Auto Cartoning Machine Fast

A production supervisor recently described a scene that plays out in packaging facilities every day: “We need to switch from a 50mm carton to a 75mm carton. The changeover should take 20 minutes. Instead, it takes over an hour. Someone is looking for the right change parts. Someone else can’t find the correct size guide rails. The machine sits idle while the team works, but not efficiently.” Changing format parts on an automatic cartoning machine is one of the most frequent and time-consuming tasks in flexible packaging operations. Yet many facilities treat each changeover as a unique event rather than a repeatable, optimizable process.

This guide provides a structured approach to changing format parts quickly and consistently—whether you have a modern tool-free machine or an older model that requires manual adjustments.

Understanding What “Format Parts” Actually Means

Before diving into the process, it helps to understand exactly which components are considered “format parts” on an automatic cartoning machine. These are the components that must be adjusted, repositioned, or replaced when you change to a different carton or product size.

The critical insight: Not every format change requires adjusting all of these components. A change that keeps the same carton width but changes only carton height requires far fewer adjustments than a change that alters both dimensions.

A 2020 benchmarking study by the Association for Packaging and Processing Technologies (PMMI) found that facilities with documented format part changeover procedures completed changes 47% faster than those without. The study also noted that 35% of changeover time was spent searching for parts and tools—not performing the actual adjustments.

The Two Types of Format Part Changes

Different approaches work for different types of format changes. Understand which type you are performing.

Type A: Same Carton Family, Minor Dimension Change

• Example: Carton width changes from 50mm to 55mm; height and depth unchanged

• Components to adjust: Magazine side guides, chain guide rails, folding rails (minor)

• Tools needed: Often none on modern machines; one or two wrenches on older machines

• Expected time: 5–15 minutes

Type B: Complete Format Change (Different Carton Family)

• Example: Switching from small square cartons for blister packs to tall rectangular cartons for bottles

• Components to adjust: Most or all of the component groups listed above

• Tools needed: Varies by machine design; modern servo machines may still be tool-free

• Expected time: 20–45 minutes

For facilities that frequently perform Type B changes, investing in automatic cartoning machines with tool-free changeover features can dramatically reduce time regardless of change complexity.

The Seven-Step Fast Changeover Process

This process assumes you have a complete set of format parts for each product family and that the parts are organized and labeled. If you are missing either of these prerequisites, stop here and address those first.

Step 1: Prepare Before the Machine Stops (External Setup)

The most efficient changeovers begin before the line stops moving. Use the final minutes of the current batch to complete all tasks that do not require the machine to be idle.

The user benefit: By completing external setup while the machine is still running, you effectively remove 20–30% of the changeover time from the downtime clock.

Step 2: Shut Down and Remove Current Format Parts

Stop the machine at the end of the batch. Remove any remaining cartons, products, and leaflets. Then remove the format parts for the completed batch.

• Work systematically from infeed to discharge (or follow your standardized sequence)

• Place removed parts directly into a labeled storage tray or cart

• Do not set parts down on workbenches or the floor—this is how parts get lost or damaged

Step 3: Clean the Machine

Before installing the next format’s parts, clean the areas where parts will mount:

• Guide rail mounting surfaces

• Magazine adjustment slots

• Sensor brackets

• Glue nozzle area (if applicable)

Residual dust or debris can prevent new parts from seating correctly, leading to alignment issues and jams later.

Step 4: Install Next Format’s Parts in Sequence

Follow a consistent sequence every time. The recommended sequence for a horizontal cartoner is:

1. Carton magazine – set side guides, backstop, and gate for new carton size

2. Transport chain and guide rails – adjust width and height

3. Folding rails (pre-fold section) – position for new carton size

4. Product infeed guides – adjust for new product dimensions

5. Product pusher or loading bucket – replace or reposition

6. Closing station – adjust folding rails, glue nozzle, compression section

7. Discharge – verify rails are set correctly

For integrated blister and cartoning lines, the blister section format change should be coordinated with the cartoner changeover. Ideally, both sections are changed simultaneously by different team members.

Step 5: Perform Initial Position Settings

Use reference marks, digital position indicators, or gauge blocks to set each component to its starting position. If your machine has saved recipes (servo-driven models), recall the recipe for the new format. The machine will automatically position servo-controlled components.

For mechanical machines, use documented settings from your changeover log.

Step 6: Verify with Test Cartons (No Product)

Before running product, manually cycle 5–10 empty cartons through the machine at low speed. Verify:

• Cartons erect properly

• Transport moves smoothly without binding

• Flaps fold correctly at each station

• Glue pattern is correct (if applicable)

Adjust as needed.

Step 7: Verify with Product at Low Speed

Run the machine at 20–30% of rated speed with product for 20–30 cartons. Inspect every carton for:

• Correct product position inside carton

• No product damage

• Proper flap folding and sealing

• Correct coding (if applicable)

Only after this verification should you ramp up to production speed.

The Tool-Free Advantage: How Modern Cartoners Speed Changeovers

The seven-step process above is dramatically faster on modern servo-driven automatic cartoners designed for tool-free changeover.

To understand how tool-free adjustment is implemented in actual equipment, you can explore the continuous and full-servo automatic cartoning machine designs that prioritize fast changeover.

Organizing Your Format Parts for Speed

Even the fastest changeover process fails if you cannot find the correct parts. Format part organization is a prerequisite for speed.

Best Practices for Format Part Storage

A Real-World Example: A contract packaging facility reduced average changeover time from 55 minutes to 22 minutes simply by organizing format parts on a rolling cart with labeled shadow-board cutouts. The cart was wheeled to the machine at the start of each changeover. Operators no longer walked back and forth to a storage room. No new machine. No new training. Just better organization.

The Changeover Log: Your Most Underutilized Tool

Facilities that change formats quickly consistently maintain a changeover log. This is not a complex digital system—a spiral notebook works.

What to Record for Each Format Change

How the Log Helps You Go Faster

• Identifies which format pairs are consistently difficult (suggests need for better parts or training)

• Tracks improvement over time (creates accountability)

• Serves as training material for new operators

• Provides data for vendor discussions about machine limitations

For facilities running monoblock configurations where blister and cartoning sections must be changed together, the changeover log should track both sections simultaneously. A mismatch in changeover time between sections creates idle time.