Automated box production in the U.S.: Aopack auto feeding & auto stacking system in real operation

As corrugated packaging manufacturers pursue higher efficiency and lower labor dependency, automation has become a key factor in modern box production lines. This project further strengthens Aopack’s presence in the United States market, supporting local manufacturers with advanced automation solutions.

In this video and project showcase, Aopack presents its Auto Feeding and Auto Box Stacking System, successfully installed at a customer site in the United States, demonstrating a higher level of automation for heavy duty box making machines.

Customer background: U.S.-based manufacturer in California

The customer is a packaging manufacturer located in Newark, California.

In August 2025, the customer installed one BM3000-HD Heavy Duty Box Making Machine, customized and optimized for the U.S. market to handle large-format and high-strength corrugated cardboard.

The machine has been operating stably and efficiently since installation.

BM3000-HD configuration for the U.S. market

The BM3000-HD installed at the customer site is equipped with advanced functions to support industrial carton production:

• Cold gluing function (no additional gluing machine required)
• Two sets of flexo printing units for logos, warning signs, and small graphic areas
• One-process conversion from raw cardboard sheets to finished carton boxes

This configuration allows the customer to complete cutting, creasing, printing, and gluing in a single production process.

Automation upgrade: Auto feeding & auto box stacking system

In January 2026, the customer received the long-awaited automation upgrade — the Auto Feeding and Auto Box Stacking System, designed to further reduce manual handling and improve production efficiency.

To ensure smooth implementation, Aopack dispatched:

• One experienced after-sales service engineer
• One R&D engineer

Both engineers supported on-site installation, commissioning, and operator training.

The complete installation and training process was completed within 5 days.

Video highlights: Automated production in action

The on-site video clearly demonstrates the automated workflow:

• Forklift feeding raw cardboard pallets onto the Cardboard Lift Platform
• Vacuum Cup Feeder with vibration separation to prevent double-feeding
• Automatic Edge Guiding for precise feeding accuracy
• Automatic carton collecting and stacking for higher output efficiency

From semi-automation to high-level automation

With the addition of auto feeding and auto stacking, the customer has significantly reduced manual labor intensity while achieving:

• More stable feeding accuracy
• Higher production efficiency
• Cleaner and more organized output stacking

This solution enables a higher level of carton production automation, especially suitable for large-format and heavy duty corrugated packaging.

Aopack automation Solutions for Box Making Machines

Aopack continues to develop modular automation solutions for corrugated box making machines, supporting customers worldwide with:

• Customized machine configurations
• On-site installation and training
• Long-term technical support

Aopack regularly presents similar automation solutions at global exhibitions and trade shows worldwide. We will attended PRINTING United Expo 2026 at Las Vegas, United States. Date: September 23–25, 2026 | Booth: N5213

Contact Aopack to learn more about automated box making solutions.

This article was originally published by Aopack.