Automated case packing is more than loading products into cartons. Based on product and packaging requirements, auxiliary materials can also be inserted into cartons automatically.

This process is called in-case insertion (or in-box insertion). By fitting a case packer with dedicated feeding and insertion modules, various materials can be placed inside cartons during packing.

Common In-Case Insertion Applications

Instruction Leaflets and Manuals Instruction sheets, user manuals and warranty cards are widely used for pharmaceutical, consumer and industrial goods. The insertion system feeds documents into each carton, matching line speed and paper format.

Desiccants Desiccants protect moisture-sensitive goods in storage and transit. For pharmaceuticals, nutraceuticals and certain food products, an automatic desiccant feeder can deliver one or multiple sachets per carton, synchronized with the case packer for stable feeding.

Corrugated Cardboard Dividers Corrugated partitions separate products inside cartons to avoid collision and offer protection during shipment. Depending on the layout, dividers can be inserted before products, between product groups or at predefined positions.

Labels and Cards ID cards, batch cards, promotional cards and internal printed labels can also be automatically fed and inserted. Insertion position and feeding method can be customized to client needs.

Other Protective Materials Other lightweight packaging materials like protective paper, cardboard sheets or cushioning materials are also available. The insertion mechanism is selected based on the material’s size, shape, thickness, quantity and target position.

How Does In-Case Insertion Work?

An in-case insertion system includes a feeding unit, detection system and insertion mechanism. Materials are separated from the magazine or hopper first, transferred to the target position and inserted into the carton at the right packing stage. Different materials need different feeding solutions, so in-case insertion is customized for actual production requirements.

Customized In-Case Insertion Solutions

No universal insertion design fits all scenarios. System design depends on:

• Material size and thickness
• Material shape and flexibility
• Number of inserts per carton
• Carton dimensions
• Product arrangement
• Insertion position
• Production speed

Pairing the right feeding and insertion mechanism with your case packer enables fully automated packaging. From leaflets and desiccants to cardboard dividers and labels, in-case insertion can be tailored for diverse packaging demands.