Cartoner Issues

⚙️ When Your Cartoner Just Won’t Cooperate: Common Causes (and How to Fix Them)

In today’s world of automation, cartoners are incredible machines that can make your life a whole lot easier. They speed up your process, improve consistency, and help you get more products out the door, faster.

That’s all fantastic… when everything’s running smoothly!

We’ve heard from plenty of customers who’ve brought in a new cartoner, only to find it’s not performing quite like they expected. Maybe the carton doesn’t open right, gets crushed, or the line keeps stopping for no clear reason. Sound familiar?

You’re definitely not alone. While every setup is unique, there are a few common reasons cartoners tend to jam — and understanding them can save you a lot of time (and frustration).

Here’s what to look for. 👇

Cartoner Issue 1: Carton Material Matters

This is one of the biggest culprits behind cartoner issues.

• Warped or curled cartons: Often caused by humidity or improper storage. 
• Creases that are too deep or too shallow: Makes it hard for the carton to pop open cleanly. If your cartons sit for several months before use, the folds can “relax” and resist opening.
• Glue flap problems: If the flaps are cut slightly too long or too short, they can snag or tear during feeding.
• Weak board stock: Cartons can collapse instead of erecting properly.
• Uneven die-cutting: Tiny burrs or rough edges can catch in the machinery.
• Design fit: Sometimes the carton design itself needs a small structural tweak to run more smoothly on automation.

Cartoner Issue 2: Machine Setup & Maintenance

Even the best cartoner needs proper setup and care.

• Feeder misalignment: If cartons aren’t picked up straight, they won’t feed correctly.
• Worn suction cups: They can lose grip over time, which means cartons don’t open fully.
• Worn parts: Chains, belts, or lugs that are past their prime can cause slipping or misfeeds.
• Glue system errors: Too much glue, too little, or bad timing can create sticky situations (literally).
• Dirty sensors: If the sensors can’t “see” what’s happening, the machine can’t react properly.

Cartoner Issue 3: Product Fit & Placement

Your product’s shape and placement make a big difference.

• Oversized or oddly shaped product: May cause flaps to catch or cartons to bulge disrupting the flow.
• Incorrect orientation or spacing: If the product goes in crooked or too early, things go sideways fast.
• Inconsistent product dimensions: Small variations between products can throw off your line’s rhythm.

Cartoner Issue 4: Operator Setup & Speed

Sometimes, it’s just about the details.

• Wrong carton size or style: Easy mistake, but it can cause major headaches.
• Quick changeovers: Missing a small adjustment between runs can lead to jams.
• Running too fast: If your materials or products can’t keep up, the machine will let you know!
• Incomplete jam clearing: A tiny scrap of crushed carton left behind can cause another jam moments later.

Cartoner Issue 5: The Environment Around You

Believe it or not, your plant’s conditions can impact performance too.

• Humidity and temperature swings: Affect how stiff the carton feels and how glue behaves.
• Dust and debris: Can clog suction cups, sensors, and moving parts.

Need a Second Set of Eyes?

If your cartoner isn’t running the way it should, don’t worry — this happens more often than you’d think.
We love helping customers troubleshoot these challenges, whether it’s a carton design tweak, a material adjustment, or identifying where the process is breaking down.

Reach out anytime — we’re happy to help you get things running smoothly again.

If you are looking for a cartoner, we would be happy to make introductions at ADCO, Serpa, or another well-established manufacturer. If you do reach out, let them know Pacific Forest sent you!