Continuous Motion · Siemens Servo Control
ZH-200 High Speed Cartoning Machine — Up to 200 Cartons/Min
The ZH-200 is a continuous-motion automatic high speed cartoning machine for pharmaceutical, cosmetic and food secondary packaging projects. Its published configuration combines a 12-head continuous pusher, three-station double planetary carton opener and Siemens servo feeding system for an output range of 80–200 cartons per minute. Product, leaflet and carton checks are configured around the approved pack format and line URS.
80–200cartons per minute, continuous motion
12-Headcontinuous pusher — gentle insertion at full speed
SiemensS7-200 SMART PLC + 3× servo axes + 7" HMI
4.1 kWtotal power · 3500 × 1270 × 1670 mm footprint
What is a high speed cartoning machine?
A high speed cartoning machine is a secondary packaging machine designed to erect flat carton blanks, insert a product and optional folded leaflet, then close the carton in a continuous production flow. The HIJ ZH-200 has a published range of 80–200 cartons per minute and uses a three-station double planetary carton opener, a 12-head continuous pusher and Siemens servo-controlled feeding. Final output depends on the approved carton, product, leaflet, feeder and upstream line conditions.
Key Takeaways
- Published output: 80–200 cartons/min. Confirm the achievable rate with representative product, carton and leaflet samples during project review and FAT.
- 12-head continuous pusher. The distributed pusher arrangement reduces the cycle demand on each head at the upper end of the published speed range.
- Outward-opening planetary carton erector. Two-stage pre-forming is designed to support stable carton opening across the approved format range.
- Product, leaflet and carton logic. Detection and stop/reject responses must be defined in the project URS and verified with challenge tests.
- International components: Siemens S7-200 SMART PLC, 3× Siemens servo axes, 7" Siemens HMI, SEW main motor, Becker vacuum pump, Schneider & Omron electrics.
- Project-specific quotation: price and delivery depend on the feeder, format parts, coding, inspection, documentation, line integration and site-service scope.
Why Buyers Choose the ZH-200
High Speed Should Not Mean High Waste
Headline speed alone does not define usable line output. Product presentation, carton opening, leaflet handling and fault recovery must work together under the agreed sample conditions. If you are still comparing formats, start with our guide on how a cartoning machine works.
12-Head Continuous Pusher
At 200 cartons per minute, each of the twelve pusher heads cycles about 16 times per minute. This distributed motion is intended to reduce the cycle demand on each pusher; product protection and insertion performance should be confirmed with representative samples.
Outward Planetary Carton Opening
The three-station double planetary wheel opens cartons by rotating outward. Two pre-forming stages, a forced pre-opening mechanism and air assistance are designed to improve carton presentation across the approved carton range.
Instant Jam-Stop Clutch
An electromagnetic clutch separates the carton chain from the main drive when the configured overload condition is detected. The purpose is to limit transmission load and make fault clearance more controlled; the stop response should be demonstrated during FAT.
Video Demonstration
See the High Speed Cartoning Machine in Action
Real factory footage — watch the continuous-motion cartoner pick, open, fill and seal cartons at production speed, with the rotary vacuum erector and leaflet folder running in sync.
What You'll See
- Rotary vacuum erector picking and pre-opening cartons at full speed
- Blister packs inserted by the 12-head dual pusher — leaflet first, product second
- Automatic leaflet folding (1–4 folds) and insertion sequence
- Optoelectronic no-product-no-carton checks running live
- Tongue-lock sealing and embossed batch coding at the outlet
Inside the Machine
Anatomy of the ZH-200 — Station by Station
Every photo below is the actual ZH-200 production machine, not a render. Follow the carton's journey from flat blank to sealed, batch-coded pack.
Station 01
Servo Carton Magazine
The carton magazine conveys blanks under servo motor control — feed timing, quantity and belt travel are all set on the HMI. A low-stock sensor alarms the operator before the magazine runs dry, avoiding unplanned stops.
Station 02
Feed Chute Buffer & Level Sensing
Carton conveying speed is regulated from the control system to maintain a usable blank stack for vacuum pick-up. Magazine settings are established with the approved carton material and geometry.
Station 03
Rotary Vacuum Erector
A three-head continuous rotary picker pulls each blank by vacuum and the double planetary mechanism opens it outward with two pre-forming stages. The published carton-stock range is 250–300 g/m², subject to sample testing.
Station 04
Product Conveyor Chain
Blister packs can arrive from an upstream blister machine on a servo-counted conveyor, with stack count set on the touch screen. Chain width and detection logic are configured for the approved pack format and reject strategy.
Station 05
Leaflet Folder (1–4 Folds)
The integrated folder inhales, separates, blows and rolls each instruction sheet through adjustable folding rollers — 1 to 4 folds, timing-belt driven with no oil lubrication. Learn more about leaflet folding and insertion.
Station 06
Leaflet Detection Logic
Leaflet-output detection can inhibit carton suction when the configured signal is absent. Leaflet-presence checks and the required stop or reject response are defined for the project and verified with FAT challenge tests.
Station 07
12-Head Dual Pusher
Each station carries a double pusher, with leaflet insertion followed by product insertion. On the configured overload signal, the moving rail retracts by cylinder and the machine stops to limit load on the product and mechanism.
Station 08
Carton Verification Sensors
Carton-feed and carton-placement sensors monitor blank presence and position. If barcode verification is included in the project scope, its code rules, alarm response and challenge samples must be defined in the URS.
Station 09
Main Drive & Overload Clutch
The SEW main motor drives through an electromagnetic clutch with sharp-angle tooth engagement. The clutch is designed to disconnect the drive under the configured overload condition and limit transmission load.
Station 10
Scaled Changeover Stations
Forming, tongue-bending and lock-box stations are modular, each with a graduated scale and handwheel — format change is visual and repeatable. See our cartoning machine changeover guide for SMED tips.
Station 11
Sealing & Batch Coding
Side-tongue and main-tongue closing use a dedicated gearbox, while the quick-release embossed batch coder can apply project-defined lot and date information. Confirm the required code format, print area and closure method before quotation. Compare options in tuck-in vs hot-melt carton sealing.
Station 12
Final Lock Inspection & Output
Outlet sensing can monitor the configured tongue-and-lock condition before cartons transfer downstream. The inspection point, reject path and challenge criteria should be included in the line URS.
Published Reference Data
ZH-200 Technical Specifications
The figures below are the published reference specification for the ZH-200 platform. The final contractual specification and FAT acceptance criteria must match the approved product, carton, leaflet and line scope.
| Production capacity | 80–200 cartons/min (continuous motion) |
|---|---|
| Carton quality | 250–300 g/m² |
| Carton size range (L×W×H) | (75–200) × (25–80) × (15–60) mm |
| Leaflet quality | 55–65 g/m² |
| Leaflet size range (L×W) | (110–260) × (100–180) mm, 1–4 folds |
| Compressed air | 0.6–0.8 MPa working pressure · 20 m³/h consumption |
| Power supply | AC 380 V · 50 Hz · 4.1 kW |
| Overall dimensions (L×W×H) | 3500 × 1270 × 1670 mm |
| Weight | 2000 kg |
| Control | Siemens S7-200 SMART (CPU ST60) + 7" Siemens SMART HMI · 3× Siemens servo axes |
Component Brand List
- PLCSiemens S7-200 SMART CPU ST60
- HMISiemens SMART 7" touch screen
- Servo drives / motorsSiemens SINAMICS ×3
- InverterSiemens 2.2 kW
- Main motorSEW (Germany)
- Vacuum pumpBecker (Germany)
- Contactors / breakersSchneider Electric
- Encoders / power supplyOmron
- TerminalsWeidmüller
Quotation scope: feeder design, format parts, coding, inspection, documentation, integration and site services can materially change price and delivery. Submit representative samples and a URS for an itemized quotation, or review our cartoning machine price guide before comparing offers.
One Machine, Many Formats
What the ZH-200 Cartons — and How It Joins Your Line
The ZH-200 handles aluminium-plastic blister plates, bottles, tubes, soft double-aluminium strips and bag-type products, and connects directly to upstream equipment through a hinged-keel climbing/turning conveyor.
Pharmaceutical
Tablet and capsule blister packs from an upstream blister line, plus bottles and pre-filled syringes with project-specific feed systems. Documentation and control requirements should be defined by the user's quality team; see cGMP requirements for cartoning machines.
Cosmetics & Personal Care
Tubes, sachets and soft packs at retail-ready speed. If your products are tubes or jars, compare the format logic in our horizontal cartoning machine page before you decide on speed class.
Food & Nutraceuticals
Bagged and sachet items, chocolate blisters and supplement bottles can be evaluated with suitable product-contact materials and feed systems. Lower-volume or frequent-changeover projects can also consider our automatic cartoning machine range.
Build a Complete Line: Blister → Carton → Case
The ZH-200 can be integrated with a blister machine through a project-specific conveyor and count-control arrangement. Pair it with our blister packing machines, or define the complete flow as a turnkey packaging solution including case packing.
Request a Line Review- ZH-200 platformBase scope
- PFS / blister feed systemProject option
- Bottle feeder systemProject option
- Commercial termsConfirmed by quotation
Honest Positioning
Continuous vs Intermittent — and Where the ZH-200 Sits
Speed class should follow your product and budget, not the other way around. Here is how the ZH-200 compares with the alternatives most buyers shortlist. Not sure about machine orientation? Read horizontal vs vertical cartoning first.
| Criteria | ZH-200 (Continuous) | Intermittent Cartoner | Higher-Output Custom Platform |
|---|---|---|---|
| Published output | 80–200 cartons/min | Varies by model and format | Defined by the selected platform |
| Pusher design | 12-head continuous, dual pusher (leaflet first) | Single reciprocating pusher | Multi-head continuous |
| Quotation basis | Feeder, formats, inspection, documents and integration | Model, formats and options | Custom engineering and line scope |
| Acceptance basis | Approved samples, URS and FAT protocol | Approved samples and FAT protocol | Project-specific performance protocol |
| Control platform | Siemens PLC + servo, English HMI | Varies by maker | Siemens / B&R / Rockwell |
| Best fit | Growing pharma, cosmetics & food plants scaling past 100/min | Small batches, frequent changeovers | Very high volume, single-SKU lines |
Forester's Insight
The most useful speed figure is the rate accepted with your product, carton and leaflet under a written FAT protocol. A cartoner also depends on the upstream machine, leaflet supply, product presentation and downstream handling, so line balance belongs in the URS.
Before purchase, define the expected response to no product, no leaflet, misfed carton, overload and downstream blockage. Ask the supplier to demonstrate each agreed challenge and record the result during FAT.
— Forester Xiang, HIJ Machinery
FAQ
High Speed Cartoning Machine — Frequently Asked Questions
Use these answers to prepare the technical discussion, then submit samples and your URS for a project-specific review.
What is the published output range of the ZH-200?
The published output range is 80–200 cartons per minute in continuous motion. The accepted project rate depends on the product, carton, leaflet, feeder, upstream supply and inspection scope, and should be confirmed with representative samples during FAT.
What products can the ZH-200 carton?
The platform can be configured for aluminium-plastic blister packs, bottles, tubes, soft double-aluminium strips and bag or sachet products. Pre-filled syringes and blister stacks require a suitable feed system. Send representative products, cartons and leaflets so the supplier can confirm feasibility and format scope.
How is the ZH-200 project price calculated?
The quotation is based on the machine platform plus product feeding, format parts, leaflet handling, coding, inspection, reject logic, documentation, line integration and site-service requirements. An itemized quote is more useful than a base price because it shows which project obligations are included.
Which FAT and qualification documents can be supplied?
The required document list must be agreed in the URS and quotation. Typical project discussions cover drawings, manuals, component lists, certificates available for supplied parts, FAT protocols and records, and support documents for the customer's DQ, IQ, OQ and PQ work. Confirm the exact deliverables before the order.
Which component brands are published for the ZH-200?
The published reference list includes a Siemens S7-200 SMART PLC (CPU ST60), 7-inch Siemens SMART touch screen, three Siemens servo axes, an SEW main motor, Becker vacuum pump, Schneider breakers and contactors, Omron encoders and power supply, and Weidmüller terminals. Confirm the final bill of materials in the quotation because component availability can change.
How are delivery, warranty and service terms confirmed?
Delivery, warranty, spare-parts coverage, FAT, installation and commissioning terms are confirmed in the formal quotation and contract after the project scope is fixed. Check the start point for the delivery period, customer site obligations, exclusions and service rates before approval.
About HIJ Machinery — Entity Reference
HIJ Machinery is a packaging machinery supplier based in Wenzhou, Zhejiang, China. Its product scope includes blister packing machines, cartoning machines, capsule filling machines, pre-filled syringe filling machines and integrated packaging-line projects.
The ZH-200 high speed cartoning machine described on this page is a continuous-motion automatic cartoner with a published range of 80–200 cartons per minute and a reference control configuration based on a Siemens S7-200 SMART PLC and three Siemens servo axes. Final specifications, documentation, compliance responsibilities and acceptance criteria are defined in the project quotation, URS and contract.
Explore the Cartoning Machine Knowledge Hub
Request a ZH-200 Configuration Review
Send your product, carton and leaflet samples, target output, coding and inspection needs, utility conditions and required documents. The engineering team can then define the feeder, format scope, FAT checks and itemized quotation.
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