Carton forming is a repetitive but essential step in many packaging processes. Opening flat cartons, forming them into shape and sealing them can require continuous manual intervention, particularly in production environments where flexibility and consistent throughput are important. 

To address this challenge, CMA Srl has developed a robotic carton-forming solution based on the JAKA Zu 12 collaborative robot. The system combines robotic carton handling, box forming and automatic taping in an integrated end-of-line automation cell.

The solution demonstrates how collaborative robotics can be applied to automate a traditionally manual packaging operation while maintaining the flexibility required to handle different carton formats. 

Automating the Carton-Forming Process 

At the center of the system is the JAKA Zu 12, a six-axis collaborative robot with a 12 kg payload and a 1,327 mm working radius. 

The cobot is equipped with a dedicated gripper designed for carton handling. During operation, it handles the flat cardboard cartons and performs the movements required to form the box. Once formed, the carton can be sealed automatically using the integrated taping module. 

This creates a coordinated process in which carton handling, forming and sealing are integrated into a single workstation. 

According to CMA, the objective of the solution is to provide a reliable automated process while substantially reducing the amount of repetitive manual work required from operators. 

Designed for Different Carton Formats 

Flexibility is a key characteristic of the CMA solution. 

The solution is designed to handle cartons ranging from 200 × 200 × 100 mm to 600 × 400 × 400 mm (L × W × H). The system can handle packages weighing up to 10 kg. 

The demonstrated configuration is designed for an average productivity of approximately one package every 20 seconds, providing a consistent operating cycle for end-of-line packaging.

The combination of the cobot's reach and payload with dedicated carton tooling allows the system to accommodate a relatively broad range of carton sizes within the specified operating parameters. 

The cell combines the JAKA Zu 12 cobot with a dedicated carton-handling gripper, automatic taping module and carton magazine. The standard configuration uses a single carton magazine, while the optional MAX2 magazine can provide increased autonomy by expanding the available capacity for flat cartons. 

An Integrated Automation Cell 

The JAKA cobot forms the core of the application, but the overall solution is designed as a complete automation cell rather than as a standalone robot. 

The hardware configuration includes the robot, carton gripper, taping system and carton magazine, while the control architecture integrates the different components of the machine.

The system is supplied with programming for: 

• HMI interface for operator control 

• Cobot software for movement and safety logic 

• PLC software for integrated management of the machine cycle 

This enables the different elements of the cell to operate as one coordinated system, from carton handling through to the completion of the packaging cycle. 

Safety Designed for Collaborative Operation 

Safety is another important part of the system architecture. 

The cell can operate without physical barriers for the specified carton formats, using safety laser scanners to monitor the working area. 

This approach supports the integration of the robotic cell into the production environment while avoiding the need for traditional physical guarding in the stated configuration. 

As with any industrial automation system, the appropriate safety configuration depends on the specific installation and its risk assessment. The barrier-free configuration described by CMA applies to the operating conditions and formats specified for the demonstrated system. 

Expandable and Adaptable to Production Requirements 

The solution is designed with additional configuration options that allow its capabilities to be expanded as production requirements evolve. 

One option is a lower conveyor equipped with an integrated taping head and motorized lateral conveying system. This can extend the handling and conveying capabilities of the cell. 

For applications requiring greater carton capacity, the MAX2 magazine can be added to increase the number of flat cartons available to the system and therefore extend autonomous operation. 

The robotic platform itself is also flexible. CMA specifies that the system is compatible with any cobot in the JAKA range, allowing the solution to be adapted to applications with different reach or payload requirements. 

This means that the automation concept is not limited to a single robot configuration. Depending on the application, the appropriate JAKA cobot can be selected to meet the required operating envelope. 

Combining Flexibility and Automation 

The carton-forming solution brings together several technologies into a single packaging workstation: collaborative robotics, dedicated carton tooling, automatic sealing, carton storage, machine control and safety scanning. 

From a technical perspective, the solution is designed around three key requirements: consistent performance, flexibility across carton formats and the ability to adapt the automation to different production environments. 

With an average throughput of one package every 20 seconds, carton dimensions ranging from 200 × 200 × 100 mm to 600 × 400 × 400 mm, and a maximum package weight of 10 kg, the MECSPE 2026 configuration provides a defined operating range for automated carton forming. 

At the same time, options such as the MAX2 magazine, lower conveyor and compatibility with different JAKA cobots allow the concept to be configured for different levels of production capacity, reach and payload. 

A Practical Application of Collaborative Robotics 

The CMA solution demonstrates how a collaborative robot can serve as the central element of a complete end-of-line packaging process. 

Rather than automating a single movement, the system brings together carton handling, forming, sealing, control and safety within one integrated cell. This approach can help manufacturers reduce repetitive manual operations while retaining the flexibility to adapt the automation to different carton formats and production requirements. 

For packaging applications where flexibility is as important as automation, the combination of the JAKA Zu 12 and CMA's integrated carton-forming technology provides a practical example of how collaborative robotics can be applied to modern end-of-line operations. 

The solution combines robotic flexibility with integrated packaging technology to automate carton forming and sealing in a configurable end-of-line cell.