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Semi-automated Packing Machine

Controlled product flow for operator-led packing.

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Manual packing is often set by the operator's own pace, which can make it hard for employers to control line speed and keep multiple SKUs moving efficiently through a shift. The PAKstation from Brillopak brings a controlled, semi-automated process to that manual workflow, with product arriving at a speed set by management rather than the operator, so manual case loading becomes a coordinated part of your production line.

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The PAKStation Explained

The PAKstation is a semi-automated system, meaning that automated conveyors coordinate the movement of products and containers while your operators carry out the packing task. Open crates, cases or trays travel to the packing position on one conveyor while another presents products from upstream within easy reach. The operator lifts and places each product into the container, retaining direct judgement over difficult, variable or defective packs.

Adjustable conveyor controls set the presentation rate. Once filled, each container is gently pushed along the outfeed conveyor by the operator to move on to the next stage. Products and containers follow defined paths, but placement remains manual.

Key Benefits of the PAKstation

Operator Friendly

Multi-format handling

The PAKstation can handle any product into any open container making itideal for complex product mixes across any industry.

Low maintenance

Operator friendly

Ergonomically designed for optimum packing performance, products andempty containers arrive directly at the working position while filled containersare guided onto the next stage by the operator, reducing reaching, turning,bending, and carrying.

Low maintenance

Low maintenance

Constructed from durable stainless steel, the PAKstation ensures exceptionalcleanliness, corrosion resistance, and minimal maintenance requirements fora long operational lifespan.

Consistent Quality

Efficient by design

Optimises manual packing by controlling line speeds throughout shifts toeliminate backlogs and boost average throughput by up to 15% per shift,saving up to one operator for every three.

compact

Compliant by design

Meets strict health and safety standards by streamlining ergonomic manual movements and reducing physical strain, lowering liability risks across yourworkforce.

Prevented Fines

Adaptable

Ideal for difficult products, multiple product change overs, or applications where full automation just doesn’t work, allowing operators to use immediate human judgement on awkward packs while conveyors manage line flow.

As-with-all-UniPAKer-installations

Retrofit-friendly

Easily integrates into existing operational lines to automate product and container presentation without requiring a full facility overhaul or extensivefloor space.

health

Scalable automation

Provides a cost-effective semi-automated foundation that optimises manual throughput today while establishing structured conveyor infrastructure forfuture fully automated upgrades.

speed

Downtime

Presenting products at a controlled rate and immediately discharging filled containers keeps fewer packs waiting at the station, eliminating short linestops and avoiding costly production backlogs.

Frequently Asked Questions

How is the PAKstation different from a manual packing bench?

The PAKstation controls how products and containers reach your operator. The operator still places every pack, but no longer sets the speed of packing. Packing therefore works at a defined pace with the upstream line.

Will it need to be replaced when we fully automate?

Not necessarily. If your line upgrades to full automation, your PAKstation can be assessed for use on another suitable line in the business.

Can it be installed on an existing line?

Yes, as long as there is sufficient space and the required conveyoring can be installed. Before finalising your system, we’ll visit your site to assess your processes, measure the available footprint and consider how the PAKstation will integrate with existing machinery.

A Cost-Effective Solution

Lower Capital Entry

If your operation doesn’t justify full automation, or the capital is unavailable, PAKstation gives you a lower entry point while still increasing efficiency, seeing aquicker ROI.

Higher Shift Yield

A more continuous packing process allows more product to be completed within the labour hours and line time already funded, resulting in lower overheads and greater finished output per shift.

Extend Asset Value

If your original packing operation is later fully automated, your PAKstation can be assessed for another compatible application, extending the potential value of the investment beyond its original line.

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Boost Efficiency and
Cut Costs with Factory Packing Automation

This guide will explain:

  • The typical issues businesses face, such as system malfunctions, packaging errors, and cybersecurity threats.
  • The initial setup costs and the specialised skills required for maintenance.
  • How to overcome these challenges and ensure a smooth transition to automation.

Want to learn more? Enter your details into the form to get instant access to our FREE guide.

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Why Choose Brillopak?

Crate-Destackers-contribute-to-fruit-producers-productivity-increase-1
We Understand Your Process

We created the PAKstation alongside live packhouse operations like Adrian Scripps to resolve real-world bottlenecks between flow-wrapping speed and manual crate loading. Grounded in the day-to-day demands of active packing lines, our engineering stems directly from a deep practical understanding of your operational challenges.

We Are Innovators In End-Of-Line Automated Solutions

Our forward-thinking designs optimise human labour through clever automation. We continuously pioneer solutions that elevate packhouse efficiency and eliminate production backlogs.

We Provide Comprehensive Support

We provide ongoing engineering support as your needs evolve. Our team provides continuous, hands-on support and tailors solutions throughout the lifecycle of your machinery.

Trusted By Food Manufacturers Across The UK

From small operations to large-scale producers.

What Our Customers Say

Real experiences from operations managers who've integrated our machines into their production lines.

I wanted a system that would be straightforward to operate, with minimal downtime and line stoppages. The new system meets that requirement. Our operators appreciate the speed at which product changeovers can now be completed at the touch of a button. Our staff understood how to operate the system after a minimal period of training.

 

Muntons

The system has minimal downtime and I am pleased to recommend Brillopak to anyone considering packing automation.

 

 

 

TATA Steel

The new apple packing lines went live on time and on budget and have already achieved a step change in the quality of product that we deliver.

 

 

 

Morrisons

I found that Brillopak were really focused on doing the job professionally. They also remained on site to make sure all of our people understood the systems before they left.

 

 

McVities

We were looking for a supplier who could meet the specification, contribute ideas and also offer the flexibility to modify their machines to work with our environment. Brillopak was a good fit.

 

 

Morrisons

ppma
PPMA Winner
Processing & Packaging Machinery Association
fp-awards-winner
Innovation Award 2021
Robotics & Automation Excellence

Let's Talk About Your Packing Line

No pressure. No hard sell. Just a conversation with someone who understands food manufacturing and can offer practical advice.

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