How to Automate Squeeze Tube Bundling and Case Packing
- Aug 5
- 4 min read
Once squeeze tubes are filled and sealed, they still need to be collated, bundled and loaded into shipping cases. This is often where automation becomes difficult.
Filled tubes can roll, lean or shift during transfer. Their tapered shape and uneven weight distribution make them harder to control than bottles, cans or cartons.
The Polypack TUBE Series addresses this challenge with robotic pick-and-place technology. The system picks up finished tubes, rotates or inverts them when needed and places them directly onto shrink film to create stable multipacks.
TUBE Series machines are available in configurations that run up to 90 tubes per minute or up to 180 tubes per minute, depending on the required production rate and application.
How Robotic Pick-and-Place Tube Bundling Works
The Polypack TUBE Series uses a patented pick-and-place system instead of pushing unstable tubes through several mechanical transfers.
The process includes six main steps:
Finished tubes enter through a controlled infeed.
Tubes are separated and positioned for pickup.
The robotic system picks up the required number of tubes.
Individual tubes are rotated or inverted when necessary.
The completed pack pattern is placed directly onto shrink film.
The film is sealed and shrunk around the bundle.
Direct placement onto the film helps preserve the orientation established by the robotic system. It also reduces the number of transfer points that can cause tipping, misfeeds or production interruptions.
Conventional Collation vs. Polypack Pick-and-Place
Conventional bundling system | Polypack TUBE Series |
Pushes products through multiple transfers | Places tubes directly onto shrink film |
Relies on lanes and guides to maintain formation | Controls the position and orientation of each tube |
Unstable tubes may roll or shift | Tubes are picked up and placed in a defined pattern |
Tube inversion may be difficult | Tubes can be rotated or inverted during placement |
Case packing may require separate equipment | Optional integrated case packer is available |
Why Tube Inversion Matters
Squeeze tubes are often wider at the sealed end and narrower near the cap. Placing every tube in the same direction can create an uneven bundle.
The TUBE Series can alternate tube orientation during placement. This positions the wider end of one tube beside the narrower end of another.
Depending on the product and pack pattern, tube inversion may help:
Improve bundle rigidity
Create a more uniform package
Reduce unused space within the bundle
Improve handling after the shrink tunnel
Use space inside the shipping case more efficiently
The correct orientation depends on the tube dimensions, cap design, filled weight and required bundle configuration.
Tube Pack Formats and Production Speeds
The Polypack TUBE Series can be configured for:
3-pack tube bundles
4-pack tube bundles
6-pack tube bundles
Custom pack patterns
Packs with or without tube inversion
Single-lane or dual-lane production
Two speed ranges are available:
TUBE Series configuration | Maximum output |
Lower-speed system | Up to 90 tubes per minute |
Higher-speed system | Up to 180 tubes per minute |
Actual throughput depends on the tube dimensions, product weight, pack quantity, tube orientation and machine configuration.
Production requirements should also be evaluated in completed bundles per minute. A six-pack application will have different cycle requirements than a three-pack application, even when the total tube rate is the same.
TUBE Series Specifications
Parameter | Specification |
Output | Up to 90 or 180 tubes per minute |
Motion type | Intermittent motion |
Infeed conveyor | Offset bucket conveyor |
Film | Dual-roll LDPE |
Lane configuration | Single or dual lane |
Seal system | Horizontal seal bar |
Pack formats | 3-pack, 4-pack, 6-pack and custom |
Optional equipment | Integrated case packer |
Final specifications are determined by the product and required line performance.
Reducing Chipboard, Dividers and Manual Packing
Tube multipacks are often placed into chipboard cartons or separated with corrugated dividers to help them remain stable inside a master case.
These materials add packaging components that must be purchased, stored and loaded.
Depending on the product and distribution requirements, a stable shrink-wrapped bundle may reduce or eliminate the need for some inner packaging materials.
Potential benefits include:
Fewer packaging components
Reduced manual handling
Lower secondary material use
Less warehouse space for cartons and dividers
More consistent multipacks
Easier automatic case loading
Completed bundles should be tested to confirm that they provide the required protection and stability throughout shipping and distribution.
Integrating Tube Bundling With Case Packing
The TUBE Series is available with an optional integrated case packer.
After the multipacks leave the shrink tunnel, they can move directly into the case packing section. The system arranges the bundles into the required pattern and loads them into corrugated shipping cases.
Combining tube bundling and case packing can provide:
Fewer product transfers
Reduced manual case loading
Consistent bundle orientation
Coordinated machine controls
A more compact end-of-line layout
Case dimensions and loading patterns should be considered during the initial design process. The orientation of the tubes inside the shrink bundle can affect how efficiently the completed multipacks fit inside the case.
What Engineers Need to Evaluate a Tube Application
Maximum machine speed alone does not determine whether a system will perform reliably.
Polypack evaluates each application using the filled product, desired pack format and surrounding line equipment.
Useful application information includes:
Tube length, width and thickness
Filled tube weight
Tube and cap materials
Current and required production rates
Number of tubes per bundle
Required tube orientation
Upstream conveyor speed and height
Shrink-film requirements
Available floor space
Case dimensions and loading pattern
Product photos, drawings or filled samples
Testing filled samples allows the engineering team to evaluate tube handling, pickup, orientation and bundle stability before finalizing the system design.
Is the TUBE Series Right for Your Line?
The Polypack TUBE Series may be a strong fit when:
Tubes roll or fall on conventional conveyors
Operators manually arrange tube multipacks
Multiple transfers are causing misfeeds or jams
Tubes need to be inverted to form a stable bundle
Chipboard cartons or dividers add material and labor
Production has outgrown manual packing
Completed bundles need to feed an automatic case packer
Each system is engineered around the actual product, production rate and desired pack configuration.
Request an Application Review
Send Polypack your tube dimensions, filled weight, required production rate and desired bundle pattern.
Our engineering team can evaluate the application, review sample products and recommend the appropriate TUBE Series speed, infeed, tube orientation and case packing options.
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