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29+ years in pharmaceutical machinery, covering capsule filling, tablet pressing, blister packaging, tablet and capsule counting, cartoning, GMP production, and overseas machine service.
Stick pack packaging is widely used in the pharmaceutical and nutraceutical industries. Powders, granules, and liquids can be packed into compact stick packs for convenient dosing, storage, and use. However, completing the stick pack itself is only one stage of the packaging process. For products sold in cartons, the stick packs must then be transferred to a cartoning machine and packed into a specified number of units per carton.
The stick pack machine focuses on forming, filling, and sealing individual packs, while the cartoner machine needs to receive those packs in a controlled and organized manner. A bag sorting machine, or bag collating and counting machine can serve as the intermediate link between the two processes. By sorting, arranging, and counting the stick packs, it helps turn randomly discharged packs into an organized material flow suitable for automatic cartoning.
This article is to take a closer look at the common challenges that can occur when cartoning stick packs and explore how a bag sorting machine addresses these challenges. What’s more, you’ll get how integrating a stick pack machine, bag sorting machine, and cartoning machine can improve the overall packaging line in terms of feeding stability, automation, and production efficiency.
Once stick packs have been produced, the next step is usually to load them into cartoner machine for secondary packaging. However, the output condition of the stick pack packaging machine does not always directly match the feeding requirements of the cartoning machine. For manufacturers, these differences can create several challenges during the transition from stick pack production to cartoning.
Stick packs in cartons
For manufacturers, stick packs entering the carton need to meet clear requirements for quantity and orientation. The cartoner machine typically needs the stick packs to be properly positioned and organized before they are pushed or loaded into the carton.
However, stick packs discharged from a multi-lane stick pack packaging machine are often produced continuously and may come out in a random or inconsistent orientation. They can overlap, stack, or arrive at different positions rather than forming the neat arrangement required by the cartoning machine.
This difference between the random output of the stick pack machine and the organized feeding requirements of the cartoner machine can create problems during downstream packaging. If the stick packs are not properly arranged before entering the cartoner, they may not be positioned correctly during loading, increasing the risk of unstable feeding, pack jams, or folding. It also makes it difficult to ensure that each carton receives the required number of stick packs in the correct arrangement.
Cartoning also requires the stick packs to be supplied in the correct quantity. For example, a product may be packed as 5, 10, 20, or another specified number of stick packs per carton. The stick pack machine, however, normally focuses on producing individual packs continuously rather than arranging them according to the final carton configuration.
This creates a second requirement between primary packaging and cartoning. That is, the continuously discharged stick packs need to be counted and grouped before they are loaded into cartons.
Without a suitable counting and grouping process, operators may have to manually collect and arrange the stick packs. This not only slows production but also increases the possibility of missing or excess packs. For pharmaceutical and nutraceutical products in particular, accurate unit counting is important because the quantity inside each carton needs to correspond to the intended packaging specification.
The third challenge is the difference in operating characteristics between the stick pack packaging machine and the cartoning machine. The stick pack machine may continuously produce packs at a relatively high speed, while the cartoner receives and loads products according to its own feeding and carton-forming cycle.
Even when the nominal capacities of the two machines are compatible, their actual material flow may fluctuate. A temporary slowdown or short stop in the upstream stick pack machine can interrupt the supply to the cartoning machine.
Without sufficient buffering and flow control, these fluctuations can lead to downstream material shortages, accumulation, or repeated machine stops. In a fully automated line, the intermediate handling stage therefore needs to do more than simply transport products. It must help balance the material flow between primary and secondary packaging.
In many production facilities, primary packaging and secondary packaging are physically separated by walls or located in different packaging areas. This creates a physical barrier between the stick pack machine and the cartoning machine.
The traditional direct connection may require a long conveying route to transfer the stick packs from the primary packaging area to the cartoning area. Additional feeding and conveying equipment may also take up considerable floor space.
For factories with limited available space or separated packaging areas, such a configuration may not be practical. As a result, some manufacturers cannot easily establish a direct connection between the stick pack machine and cartoning machine and instead rely on manual cartoning after the stick packs are produced.
However, manual cartoning introduces another requirement. Operators still need to sort and count the stick packs before putting the correct quantity into each carton. Therefore, even when a fully automatic connection is not feasible, there is still a need for an efficient solution to handle the intermediate sorting and counting process.
The challenges described above mainly occur because the stick packs leave the primary packaging process in a continuous but relatively unorganized flow, while the cartoner machine requires packs to be presented in a specific quantity, orientation, and arrangement.
This is where the bag collating and counting machine plays an important role. Positioned between the stick pack and cartoning processes, it takes the finished stick packs and prepares them for downstream carton loading. The following part is to explain how the machine operates and how each stage addresses the challenges encountered during stick pack cartoning.
A bag sorting machine is an intermediate packaging-line machine designed to receive randomly discharged stick packs or sachets, organize and count them, and provide a controlled flow for downstream equipment such as a cartoning machine.
In a stick pack cartoning line, its position is typically between the stick pack machine and the cartoning machine. The bag sorting machine can bridge the gap between the output characteristics of the primary packaging machine and the feeding requirements of the cartoner.
RQ-PA-400 Bag Sorting Machine from Rich Packing
First, stick packs enter the bag sorting machine through a matrix-based and multi-stage powered feeding system. The multi-stage feeding design helps prevent stick packs from being squeezed against each other during feeding and ensures a continuous material supply. The hopper is also designed to minimize residual stick packs at the bottom, allowing feeding to continue without manual intervention. This provides a more stable connection between the continuous output of the stick pack packaging machine and the downstream sorting process.
matrix-based and multi-stage powered feeding system
The stick packs then pass through the roller-based separation section. When multiple packs are stacked or arrive together, the rollers separate them into a single-file flow. This prevents piled or connected packs from continuing downstream as a group and creates the basic feeding condition required for accurate arranging and counting.
In particular, to coordinate the movement of rollers and separate stick packs precisely, 11 servo motors are connected. The servo control system precisely synchronizes output with the movement distance and timing of the rollers, enabling rapid start-stop response and high motion-control accuracy. As a result, stick packs can be arranged continuously and smoothly instead of accumulating or moving irregularly.
After the packs are separated and arranged, a camera-based vision inspection and computerized control system detects their orientation and automatically correct the direction when necessary. This is of high importance for stick packs coming from multiple lanes, where packs may leave the stick pack machine in different orientations. By correcting their direction before cartoning, the bag collating and counting machine helps ensure that the packs enter the cartoning machine in a consistent position and orientation.
Then, the bag sorting machine will count and group these stick packs according to the preset quantity. For example, if each carton requires 10 stick packs, the system can automatically count and organize the packs into groups of 10 before feeding them to the cartoner machine through conveyor belt. The counting error rate is below 0.009%, helping maintain stable quantities in each box.
Photoelectric sensors of rich packing’s bag sorting machine
What’s more, to maintain stable operation throughout the process, the feeding, conveying, arranging, and separating stations are equipped with motion-control systems and photoelectric sensors with real-time feedback.
In this way, each function of the bag sorting machine directly addresses specific challenges in stick pack cartoning. The multi-stage feeding system provides a continuous and stable material supply, reducing the impact of operation fluctuations between the stick pack machine and cartoning machine. Roller separation prevents piled and connected packs from entering the downstream process together, while servo-controlled arranging creates a consistent and orderly flow. The vision inspection system corrects improper pack orientations, and automatic counting and grouping ensure that each carton receives the required number of stick packs.
Therefore, the bag sorting machine is not simply a conveying device between two machines. It acts as a control and transition system between primary and secondary packaging, converting randomly discharged stick packs into accurately counted, correctly oriented, and consistently arranged groups that are ready for automatic cartoning.
Well-organized electric cabinet of rich packing’s bag sorting machine
A bag sorting machine can solve the intermediate handling challenges, but its full value becomes clearer when it is considered as part of the complete stick pack cartoning line. This part looks at how three machines work together, and examines the overall benefits of integrating them into one packaging solution.
A complete stick pack cartoning line connects three key stages: stick pack production, sorting and counting, and cartoning. Each machine performs a different function, and the conveyors between them create a continuous material flow from primary packaging to secondary packaging.
The packaging line starts with the stick pack machine, which completes the primary packaging process. In this stage, the machine performs film forming, materials filling, sealing and cutting to produce individual stick packs. After production, the finished stick packs are collected and transferred to the next stage.
The stick packs are then loaded into the hopper of bag sorting machine. Once the stick packs enter, they go through the feeding, separation, arranging, orientation correction, and counting processes described in the previous section. The sorting machine converts the randomly discharged packs into organized groups with a defined quantity and consistent orientation. These prepared groups are then transferred toward the cartoning machine through conveyor.
The cartoner machine receives the organized stick packs and completes the secondary packaging process. It opens the carton, feeds the required number of stick packs and information leaflet into the carton, and then completes closing and other downstream operations according to the configured packaging process.
The conveyors do more than simply transport products. They help establish a stable transition between different processing stages. This creates a more coordinated material flow and reduces the need for manual transfer between individual machines.
The division of functions allows each machine to perform the process it is designed for while the conveyors and control systems connect the individual stages into one packaging workflow.
The main advantage of integrating the three machines is that it connects the primary packaging and secondary packaging processes into one continuous production system. Instead of treating stick pack production and cartoning as two separate operations, the finished packs can move directly from one stage to the next with minimal manual intervention.
In a typical production facility, the stick pack machine belongs to the primary packaging stage, while cartoning belongs to secondary packaging. The two processes may be located in different production areas because of the factory's layout and packaging-room arrangements.
The bag sorting machine provides a simpler intermediate solution. It receives the finished stick packs after primary packaging and processes them into organized and accurately counted groups before they proceed to secondary packaging. This allows the two packaging stages to work together without requiring the entire production layout to be built around a long direct connection.
The flexible configuration is also important for factories where available floor space is limited or where primary and secondary packaging areas are physically separated.
Rather than requiring a long connection between the stick pack machine and cartoner machine, manufacturers can position the sorting equipment according to their actual production layout. The focus is therefore not simply on connecting machines over the shortest possible distance, but on creating a practical material-handling process within the existing factory environment. This gives manufacturers greater freedom when planning or upgrading their packaging areas.
Another advantage is the reduction of manual intervention between primary and secondary packaging. Manual collection and refeeding not only require additional labor but also lead to more risks for incorrect counting, disordered packs, or feeding interruptions.
By automating sorting, orientation correction, counting, grouping, and transfer, the integrated line simplifies the transition between machines. Operators no longer need to repeatedly intervene just to prepare stick packs for the next packaging stage. This makes the overall process more suitable for manufacturers pursuing higher levels of packaging automation.
The integrated packaging line can also improve production efficiency by reducing repeated manual operations. Without an automatic sorting and counting stage, operators may need to collect randomly discharged stick packs, separate them, count them, arrange them, and repeatedly supply them to the cartoning machine.
With the bag sorting machine acting as an intermediate processing stage, these tasks are performed automatically while the production line is running. Operators can therefore focus more on equipment monitoring, material supply, quality inspection, and production management rather than repetitive pack handling.
The improvement is not simply a matter of increasing machine speed. It comes from reducing interruptions and unnecessary transfers between processes, allowing the upstream and downstream machines to operate as a more continuous system. In this case, it can reduce cost for pharmaceutical and nutraceutical manufactures.
The integrated configuration also improves the continuity of material flow. The stick pack machine and cartoner machine may have different operating characteristics, and their actual output can fluctuate during production. The connecting conveyors and sorting system provide an intermediate transition between the two processes.
This means that a temporary change in the output of the stick pack packaging machine does not necessarily have to be transferred directly to the cartoner. The sorting and conveying stages can help maintain a more controlled supply of packs to the cartoning process. For production lines running for extended periods, this type of coordinated material flow can be important for reducing unnecessary stops and maintaining a more stable production rhythm.
Servo-controlled rollers
Before reaching cartoner machine, the stick packs have already passed through separation, arrangement, orientation correction, and counting. The cartoning machine therefore receives material in a more consistent condition than it would from a randomly discharged stick pack machine. This helps create greater consistency in carton loading, particularly when each carton must contain a fixed number of stick packs arranged in a specific way.
This is particularly valuable for pharmaceutical and nutraceutical products, where maintaining controlled material flow and reducing unnecessary manual contact can contribute to a more consistent packaging process.
The packaging line can be adapted to different production requirements. The stick pack machine can be selected according to the product and required output. The bag sorting machine can be configured to handle the corresponding flow, counting requirements, and arrangement pattern, and the cartoning machine is configured according to the carton dimensions and required number of packs per carton. Thus, manufacturers can build a packaging line on the basis of their actual production requirements.
Rich Packing’s stick pack cartoning line
Connecting a stick pack packaging machine with a cartoning machine can involve several challenges, including unstable material flow, and difficulties in counting and grouping packs for downstream cartoning. A bag sorting machine provides effective solution by taking over the intermediate preparation of the stick packs.
Through controlled feeding, separation, arranging, orientation correction, and automatic counting, the bag collating and counting machine transforms the output from the stick pack process into an organized and carton-ready material flow. In this way, it serves as an important link between primary stick pack production and secondary carton packaging.
At Rich Packing, we can provide professional stick pack packaging line solutions based on your production needs, pack specifications, capacity, and carton packaging requirements. Our solutions include advanced bag sorting machines as well as the complete stick pack cartoning line, with professional installation, commissioning, and operator training to help customers achieve a smooth and reliable production process.
A bag sorting machine is used to organize and prepare randomly discharged stick packs before they enter the cartoner machine. It can perform separation, arranging, orientation correction, counting, and grouping, helping provide the cartoner with a more controlled and organized flow of stick packs.
A stick pack machine focuses on producing individual stick packs continuously, while a cartoning machine requires the packs to be supplied in a specific quantity, orientation, and arrangement. The bag sorting machine bridges this difference by preparing the stick packs for downstream carton loading.
Yes. The bag collating and counting machine can automatically count and group stick packs according to a preset quantity. For example, if each carton requires 10 stick packs, the machine can count and organize the packs into groups of 10 before sending them to the cartoning machine. The counting error rate is below 0.009%.
Yes. The machine uses a camera-based vision inspection and computerized control system to detect the orientation of the stick packs and automatically correct their direction when necessary. This helps ensure that the packs enter the cartoning machine in a consistent orientation.
Yes. The equipment configuration can be designed according to the customer's product, stick pack specifications, required output, quantity per carton, carton dimensions, and other production requirements. This allows the stick pack machine, bag sorting machine, and cartoning machine to be configured as a complete packaging solution.
29+ years in pharmaceutical machinery, covering capsule filling, tablet pressing, blister packaging, tablet and capsule counting, cartoning, GMP production, and overseas machine service.
E-mail : manager@richpacking.cn
Building D, No. 226, Beishan Qiaotou Street, Haizhu District, Guangzhou City, Guangdong Province, China
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