Case Study: Johnson & Johnson MedTech Automates Tube Bundling with Polypack’s TUBE-180 Shrink Wrap Machine

Johnson & Johnson MedTech is known for leading innovation in the healthcare space. As part of their ongoing drive to optimize production and reduce costs through automation, they partnered with Polypack to implement a customized bundling and shrink wrapping solution for individual medical tubes.

The result: the Polypack TUBE-180, a high-performance system designed to automate the bundling of loose tubes with precision, speed, and consistency. With this machine, Johnson & Johnson eliminated the need for cardboard inner packs and manual packing labor, delivering over $400M+ in annual savings, mostly from material reduction, and increasing line speed by 20%.

Precision Engineering for Complex Product Handling

The packaging process begins with dual infeed conveyors, which receive tubes lying down with the cap leading. From there, the tubes accumulate in groups of three onto elevator platforms, which lift the product slightly into position for transfer.

At the next stage, suction transfer assemblies pick up each group of three tubes using vacuum cups. The center tube can be rotated 180 degrees if needed, while the side tubes are positioned accordingly. The three tubes are then placed side-by-side onto a sheet of film on the bucket conveyor.

This process repeats to place a second row of three tubes onto the same sheet, forming a 6-pack. Once the six tubes are positioned, a top layer of film is applied, and the product passes through a seal bar assembly, where the film is cut and sealed around the bundle.

The sealed bundles continue through a shrink tunnel, which uses controlled heat and airflow to shrink the film tightly around the tubes—creating a clean, secure, and tamper-evident package.

Results That Go Beyond the Machine

From the beginning, Polypack worked closely with Johnson & Johnson to ensure the TUBE-180 met all technical and operational needs. Installation, training, and ramp-up were seamless—thanks to detailed planning and collaboration between teams.

“As part of our ongoing initiative to reduce overall costs through automation, the Polypack automated tube bundler was successfully launched. A structured startup ladder helped our operators and maintenance team apply the knowledge gained during training, and the machine ramped up quickly and efficiently. This new bundler has allowed us to eliminate cardboard inner packs and reduce manual packing labor, resulting in over $400M+ in annual savings, primarily in material costs. Additionally, by removing manual packing, we've increased line speed by 20%, unlocking even more cost-saving potential.” — Petty Manthe, New Product Introduction Project Leader, Johnson & Johnson MedTech

Smart Automation for the Future

The TUBE-180 has become a critical component in Johnson & Johnson’s packaging operations, delivering high-volume output while improving consistency and reducing waste. With expert engineering, responsive service, and a commitment to excellence, Polypack continues to help customers like Johnson & Johnson automate with confidence.

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