Custom Case Packer Machines

Aagard case packers are purpose-built secondary packaging systems that automatically load and seal products into cases at production speeds—configured to your product, case style, and line layout. Each system is designed for a small footprint, fast changeover, and seamless integration with upstream and downstream equipment.

Built for food and snack, beverage, dairy, meat and cheese, pet food, health and personal care, and other consumer goods manufacturers, Aagard case packers are engineered to your application, not pulled from a catalog. If your line has high SKU variety, frequent changeovers, a constrained footprint, or integration requirements that a standard machine can't handle reliably, that's exactly where Aagard's application-first engineering approach is designed to help.

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High Speed Fully-Automated CPG Variety Case Packing System

Aagard Reverse Flow Knock Down Case Packer

Built Right, Supported for Life

Every machine includes our free, lifetime remote support: Aagard Assurance™. Your dedicated Assurance Manager provides proactive check-ins and expert guidance to keep your systems at peak performance.

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Tell Us About Your Project

Not sure which configuration fits your line? Talk to one of our engineers about your line automation goals.

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Where Aagard Case Packers Are Used

Built for the Case Packing Challenges Standard Machines Can't Handle

Most manufacturers don't come to Aagard because they need a case packer. They come because they have a specific problem on the line that a catalog machine couldn't solve.

The scenarios below represent the most common situations. If your line matches one of them, an Aagard system is likely worth a closer look.

Production Scenario	Configuration Match
Manufacturer needs to automate case packing to reduce labor and keep the line running consistently at target rates	Primary case packer system engineered to product, case style, and line rate
Line runs frequent SKU, pack style, or case count changes and needs faster, repeatable changeovers	RapidLaunch™ (Monitored or Automatic)
Brand is launching or expanding variety packs and needs a flexible system without dedicated equipment for every SKU	Flexible case packer configured for multi-format and variety pack handling
Floor space is tight and the customer wants to combine multiple operations into one compact, integrated cell	Integrated packaging cell combining case packing with inspection, labeling, or other end-of-line functions
Application requires a specific case style or loading approach (RSC, HSC/display, wrap-around; top-load, side-load; pick-and-place or robotic)	System engineered around the specific case handling and loading strategy

Aagard is a great fit for when a buyer requires flexibility, integration, or compact footprint.

Not Sure If a Case Packer Is Right for Your Line?

Engineering Kickstart is a structured, application-first evaluation in which you work directly with Aagard engineers to define requirements, explore concepts, and align on the right configuration before committing to a full build. It reduces risk up front.

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About Our Process

Configure Your Case Packer Around Your Line

Every Aagard case packer starts with your application: your product, your case format, your line rate, and your operational goals. From that baseline, you select from a documented set of options organized around the outcomes that matter most to your team.

The options below represent our most commonly configured selections, not the full scope of what's possible. Our team is happy to discuss anything not listed here.

Automation & Loading

The foundation of your system. These options define the core case packer configuration and how it handles your product and case format.

Option	What It Delivers
Primary Case Packer System	Purpose-built secondary packaging system engineered to your product, case style, loading approach, and line rate
Robotic/Vision-Guided Loading	Adds robotic or vision-guided loading capability for applications requiring flexible product handling or orientation
Integrated Inspection/Barcode Scanning	Confirms product presence, count, or identity in-line to reduce errors and support quality requirements
Integrated Checkweigh/X-Ray	Adds in-line weight verification or X-ray inspection when application or compliance requirements demand it
Case Magazine/Extended Buffering	Reduces operator involvement by extending case blank capacity and supporting longer uninterrupted runtimes
Automatic Reject Handling	Removes non-conforming cases from the line automatically, reducing manual intervention and downtime

Glue & Sealing Systems

For lines where sealing method, reliability, and maintenance burden drive the specification.

Option	What It Delivers
Adhesive	Nordson ProBlue Flex Glue System is an industry-leading hot melt system with autofill capability, clean installation, and a strong service network, chosen for reliability and minimal maintenance burden. Adhesive systems from other manufacturers are available upon request.
Tape Sealing	Engineered when the case style, plant standard, or customer requirement calls for tape rather than hot melt

Changeover, Controls, & Operator Experience

For lines running multiple SKUs or formats, or where operator usability and training are a priority.

Option	What It Delivers
RapidLaunch™ (Monitored)	Guided changeover with verification helps teams restart faster and reduces setup errors after format changes
RapidLaunch™ (Automatic)	Automates adjustments where practical to minimize downtime and reduce operator burden during frequent changeovers
Changeover Verification Devices	Confirms setup is correct before the line restarts, reducing errors and waste on the first cases after a changeover
RapidLearning™ Package	HMI-embedded training tools, guides, and troubleshooting resources that help operators get up to speed faster and reduce reliance on tribal knowledge
Additional HMI	Adds an extra operator station for better line access on larger systems or multi-sided workflows
FactoryTalk Optix HMI	Provides an enhanced operator experience with richer diagnostics and embedded training and documentation on the HMI
Training Videos	Embeds step-by-step changeover and operational guidance directly in the HMI

Compliance & Standards

For facilities with specific regulatory, plant, retailer, or food safety compliance requirements.

Option	What It Delivers
Metal Detectable Wire Ties	Reduces contamination risk in food-grade environments
Food Grade Lubricant	Meets food-safe lubrication requirements for applicable contact points
UL Electrical Panels	Provides UL-labeled control panels to support compliance and plant standards in the U.S. and Canada
Circuit Breaker Upgrade	Available when application or plant electrical standards require it

Diagnostics, Integration, & Visibility

For engineering teams evaluating how the case packer connects to the rest of the line and to Aagard's service team.

Option	What It Delivers
LED Diagnostic Lighting	Improves visibility at key access points and helps teams troubleshoot faster when a fault occurs
Forensics Camera System	Captures video of events around stops to speed root-cause analysis and reduce repeat downtime
Remote Support (24/7)	Enables Aagard service to connect remotely for faster troubleshooting and reduced time to recovery
Ethernet IP Module	Connects the case packer to your plant network for data exchange and line visibility
Network Architecture	Defines how the system integrates with your plant's OEE, data, or control infrastructure
Case Printing Integration	Integrates customer-specified print systems into Aagard controls and diagnostics for in-line printing without a separate station
Case Labeling Integration	Integrates customer-specified print-and-apply or labeling systems into the machine controls for in-line labeling

What Every Aagard Case Packer Includes as Standard

Engineering & Safety Standards Built into Every Machine

Before you select a single option, every Aagard case packer ships with a documented baseline of engineering, safety, and controls standards. The foundation is consistent and proven. The configuration builds on top of it.

Every Aagard case packer ships fully tested before leaving the facility. Controls, safety circuits, and key machine functions are verified prior to shipment. When materials are available and the project scope includes it, a full run-off with customer product and materials is completed.

Standard	What It Means for Your Line
Category 3 Safety Architecture	Built with Category 3 safety architecture, including interlocked guarding and controlled stop sequences, documented and consistent across all Aagard machine categories
Pilz Guard Switch	Mechanical locking and release - High safety / clear lock state
NEMA 12 Rated Electrical Panels	Control panels rated for industrial environments; UL-labeled panels available when required by customer spec
UL-Certified Electrical Components	Electrical components are UL-certified as standard
Rockwell Automation Controls Platform	Controls architecture built on a documented, serviceable platform with broad parts availability
Single Unified Controls Architecture	Upstream and downstream equipment can be integrated under one control system, reducing handshakes and simplifying troubleshooting
HMI-Embedded Documentation	Maintenance guides, changeover instructions, and reference materials accessible at the machine
Documented Machine Standards	Every build references Aagard's documented standards, so your engineering team knows what they're getting before the project starts

How a Custom Case Packer Project Works at Aagard

One of the most common hesitations on a custom machine project isn't the machine itself. It's not knowing what happens after you fill out a form. Here's the full path from first conversation to a commissioned system running on your floor.

Application Discussion

Every project starts with a conversation about your application: what you're running, your line rate, your footprint, and your goals. This is an engineering intake, not a sales call.
Engineering Kickstart

Engineering Kickstart is the standard entry point for all Aagard projects. It's a structured, application-first evaluation where you work directly with Aagard engineers to define requirements, explore concepts, and align on the right configuration before committing to a full build, in order to reduce risk up front.
System Design & Build

Once requirements are defined and scope is locked, Aagard engineers design and build your system. This phase includes controls architecture, mechanical design, integration planning, and documentation. Your engineering team has visibility into the process and clear handoff points.
Factory Acceptance Test (FAT)

Every system goes through standard pre-shipment testing before it leaves Alexandria, MN. For projects where scope and preference support it, an expanded FAT demonstration package is available so your team can witness performance firsthand before the machine ships.
Installation & Commissioning

Aagard technicians handle installation and commissioning at your facility. Installation and commissioning estimates, along with shipping estimates, are provided with your quote. Timelines depend on system complexity and site readiness.
On-Site Training

Operator and maintenance training is included as part of the commissioning package. Additional training is available as your team grows or shifts change.
Ongoing Support via Aagard Assurance™

After go-live, your line is supported through Aagard Assurance™: a dedicated account contact, a spare parts list for your specific configuration, and 24/7 remote service availability via TeamViewer.

Why Teams Choose Aagard

Purpose-built for your line, not pulled from a catalog. Here's what that means in practice:

Reduced manual case packing labor and improved throughput stability across all shifts

Faster, repeatable SKU and format changeovers using RapidLaunch™ guided or automatic changeover

Flexible multi-format and variety pack capability without dedicated equipment for every SKU

Small-footprint, integrated system designs that combine multiple end-of-line operations into one compact cell

Operator-first usability with RapidLearning™ HMI-embedded training and troubleshooting tools that reduce reliance on tribal knowledge

Consistent case quality with controlled loading, sealing, and integrated inspection or reject handling when required

Proven, documented controls architecture designed for long-term maintainability and integration confidence

Category 3 safety architecture with interlocked guarding and practical operator and maintenance access

Integrated upstream and downstream equipment and third-party devices (printing, labeling, inspection) under one unified controls experience

Aagard Assurance after go-live: a dedicated Assurance Manager, proactive check-ins, and 24/7 remote customer support included free with every machine

Case Packer FAQs

Does Aagard make fully custom case packers, or are they based on standard configurations?

Aagard case packers are built from proven standards and configurable options, then engineered around your application.

How do I evaluate a case packer without published specifications?

Start with your application: what you're packing, your case format, your line speed, and your changeover requirements. Aagard's engineering team uses that information to scope the right system. Our Engineering Kickstart is designed specifically for this early evaluation phase. Aagard will help you define success criteria (rates, changeovers, integrations, and constraints) and recommend the right configuration—then validate it through pre-shipment testing (FAT).

Can the case packer handle multiple SKUs or case formats?

Yes. Aagard case packers are configured around your product and format mix. Rapid Launch™ changeover options—both monitored and fully automatic—are available to reduce format change time and support multi-SKU lines without extended downtime between runs. Capability depends on the product range and case styles; we typically recommend Rapid Launch™ options when SKU and format changes are frequent or downtime is costly.

Can Aagard integrate case printing and labeling into the same system?

Yes. Aagard integrates customer-specified print-and-apply and print systems into Aagard controls and diagnostics, keeping printing and labeling in-line rather than requiring a separate downstream station. This gives operators one consistent operating experience across the full system.

What glue system does an Aagard case packer use?

The Nordson ProBlue Flex is commonly specified as the hot melt glue system across Aagard case packers. It features autofill capability, clean installation, and a strong service network, chosen for reliability and minimal maintenance burden. Tape or other sealing methods can be engineered when required by the case style or customer standard.

What safety standards does an Aagard case packer meet?

Every Aagard case packer is built with Category 3 safety architecture, including interlocked guarding and controlled stop sequences. Electrical panels are NEMA 12 rated with UL-certified components. UL-labeled panels are available when required by customer spec. Safety architecture is documented and consistent across all machine categories.

What support is available after the machine is commissioned?

Aagard Assurance is included free with every Aagard machine and provides a dedicated Assurance Manager as your single point of contact, proactive check-ins, and 24/7 remote customer support. Field service technicians are available for on-site needs. HMI-embedded documentation and RapidLearning™ training tools are accessible at the machine to help operators troubleshoot and train new team members faster.

What case styles can Aagard case packers run?

Aagard case packers are commonly engineered for RSC and HSC/display cases, as well as wrap-around and other application-specific formats. During the application review, we confirm case style, product orientation, and sealing method so the system is built around the right case handling and loading strategy for your line.

What information do you need to quote a case packer?

To scope the right system, we typically start with: product details (dimensions, fragility, orientation), pack pattern and case count, case style and blank details, target rate and uptime expectations, SKU and format changeover needs, available floor space and line layout, and any required integrations (printing, labeling, inspection, upstream and downstream equipment). The more complete the information, the faster we can recommend a configuration and provide an accurate quote.

What does a typical changeover look like, and how do Rapid Launch™ options help?

Changeovers vary by product range and case format, but the goal is always the same: make setup repeatable and reduce downtime between runs. Rapid Launch™ changeover options can add monitored setup steps and automation so operators can follow guided changeovers, reduce setup errors, and return to production faster. This is especially valuable on lines with frequent SKU or format changes.

How do you validate performance before shipment?

Every system goes through structured pre-shipment testing to confirm functional operation and the project's agreed acceptance criteria. Depending on the project, this may include running specific products and case formats, verifying changeovers, and proving integrated devices. A customer-witness FAT or expanded demonstration package can also be scoped when needed.

Can the system be designed for a small footprint or to combine multiple end-of-line operations?

Yes. Many Aagard systems are engineered to fit tight plant layouts and can be designed to combine multiple end-of-line functions into one integrated cell when it improves flow and reduces floor space. During early discovery, we review your layout constraints and decide what operations should be integrated versus kept separate.

How do you handle integrations with upstream and downstream equipment and third-party devices?

We design the case packer as part of the line, not a standalone machine. That means confirming interfaces early (infeed and outfeed, line speeds, communications), then integrating customer-specified devices like print-and-apply, inspection, or barcode scanning into the system's controls and diagnostics so operators have one consistent operating experience.

Do you offer tape sealing in addition to hot melt, and how is sealing selected?

Hot melt sealing is common, but sealing method is ultimately selected based on the case style, plant standards, and performance requirements. If your application requires tape or another sealing approach, we can engineer the system around that requirement during the application review and design phase.

What is the typical project timeline or lead time, and what drives it?

Lead times vary based on scope and complexity. The biggest drivers are the number of SKUs and case formats, level of integration with upstream and downstream equipment and third-party devices, required standards or compliance needs, and availability of customer-provided product and packaging materials for testing. After an initial application review or Engineering Kickstart, we can provide a more accurate timeline with your quote.

Tell Us About Your Line

We'll Tell You How We'd Build for It

Do you have a specific situation at the end of your line that off-the-shelf equipment hasn't handled well?

Tell us about it. Aagard will follow up to schedule a short application discussion to understand your product, speed, layout, and goals. From there, we'll recommend the best-fit configuration and next steps.

Custom scope. Documented standards. Proven implementation. Built in Alexandria, MN.