Bid Farewell to Bottlenecks of Manual Box Folding! Ruili Packaging Customizes Automated Assembly Line for Omron, Boosting Production Capacity by Over 40%

As a global benchmark enterprise in industrial automation, Omron’s production workshops have long been hampered by a "hidden process"—the finished product packaging stage still relied on manual labor for the full workflow of carton forming, lining placement, flap folding and carton sealing. Each carton took more than 3 minutes to process. This not only drove up labor costs but also caused inconsistent carton sealing precision due to varying manual operations, forming a critical bottleneck holding back production line efficiency gains.

To address this pain point, Ruili Packaging Technology (Shanghai) Co., Ltd. conducted in-depth on-site investigations at Omron’s production facility. Taking into account the workshop’s usable space of 15 meters by 9 meters, the company tailor-made a fully automatic horizontal integrated assembly line covering carton opening, product loading and carton sealing. Standardized equipment replaced repetitive manual work, delivering a qualitative leap in packaging performance.

Packaging Assembly Line Solution Layout

The complete solution complies with industrial-grade stability standards, and all core equipment has passed working condition adaptation verification:

The front end is equipped with the RL-ZDK5050 automatic carton erector, capable of forming 20 to 23 cartons per minute. It comes with a buffer storage compartment for 80 to 100 cartons, completely eliminating manual carton preparation.

Connected to Ruili’s self-developed unpowered roller conveyor line, paired with an automatic gripping robotic arm that accurately places paper liners with a positioning error controlled within ±1 mm.

The mid-section adopts the RL-ZDF5050 automatic flap folding and sealing machine, compatible with all product specifications weighing 5 to 20 kilograms. Its worktable height is adjustable from 600 mm to 730 mm, achieving over 98% flatness in carton sealing.

The tail end is fitted with the RL-ZDJ5050 automatic edge & corner sealer. Featuring secondary carton pushing and staggered movement design, it resolves jamming issues common to traditional corner sealing equipment, with a maximum single-machine throughput of 40 cartons per minute.

Three sets of safety protection devices are installed across the entire line, accompanied by a one-year full-cycle warranty and free operational training, fully eliminating customers’ worries about equipment maintenance and operation.

The solution reserves an interface for an automatic labeling machine to support future functional expansions. All equipment is compatible with 3-inch machine cores, fully matching Omron’s existing packaging material standards.

The upgraded automated assembly line realizes true "unmanned packaging": a single line requires no dedicated on-site operators. Supported by automatic printing, positioning and labeling systems, labels are placed with consistent precision. Only a small number of staff are needed to assist with mid-stream product loading. Compared with the traditional manual box folding model, overall packaging efficiency has seen remarkable improvements. While freeing up labor resources, the system further ensures consistent, reliable carton sealing and product labeling.

This upgrade not only eliminates quality fluctuations caused by manual operations but also provides robust support for Omron’s subsequent production capacity expansion and flexible manufacturing.

RL-ZDK5050 Automatic Carton Erector

RL-ZDF5050 Automatic Flap Folding & Sealing Machine

RL-ZDJ5050 Automatic Edge & Corner Sealer

As an integrated solution provider with 23 years of deep expertise in the packaging industry, Ruili Packaging consistently focuses on "delivering quantifiable value to customers". Globally, only two enterprises are authorized to print their logos on clients’ finished products—one is Tetra Pak, and the other is Ruili (Reallay). This trust stems from our relentless pursuit of superior quality: customers opt to display our brand because it symbolizes reliable performance and market-recognized premium quality. Much like how we supported enterprises in the Xiaomi ecosystem to build complete product packaging systems from scratch, Ruili offers far more than packaging consumables; we elevate the overall commercial appeal of products through optimized packaging solutions.

The successful rollout of this automated project for Omron stands as solid proof of this philosophy. Rather than simply replacing manual labor, we transform packaging from a "cost center" into an "efficiency driver" via standardized workflows and data-driven production capacity, with one full year of stable operation verifying the empowering effects of automation retrofitting.

Amid the restructuring of supply chains driven by the new retail landscape, Ruili recognizes that service lies at the core of competitiveness. We strive to lower customers’ error and decision-making costs, enabling small and medium-sized enterprises to access world-class supply chain support on par with Fortune Global 500 corporations. After all, product differentiation is hard to achieve amid cutthroat market competition, yet packaging serves as the only tangible touchpoint that resonates with end users. Today, through full-category coverage and data-based management, we streamline complex packaging supply chains to boost efficiency, continuously empowering outstanding enterprises to scale new heights.