Optimized Design for the Flap Folding System of a Carton Sealer Machine by Automation

This study presents the design and implementation of an automated flap folding system for a carton sealer machine in a beverage manufacturing industry in Indonesia. The system addresses the inefficiencies of the manual folding process. The design focuses on affordability by employing a fully electric system, eliminating the need for additional compressors and air tubes. Fabrication utilizes materials available in the company's workshop, with a total cost of IDR 7,243,452. Testing reveals that the system's maximum capacity is 36 cartons per minute, surpassing the current capacity of the carton sealer machine. This results in a production increase from 19 cartons per minute to 30 cartons per minute (58%). Additionally, this research offers substantial cost savings compared to purchasing new carton sealers with automatic flap folders, with potential savings of IDR 45,000,000 per machine if the system is mass-produced.