Battery Sorting, Honeycomb Tray Forming and Case Packing Line

This is a five-module line, and the design principle throughout is that the differences between the three families are held in recipes, not in hardware. **Battery orienting and sorting module.** Cells are oriented and sorted from the 550 ppm infeed so that each downstream module receives a stream of the right cell. **Honeycomb separator forming and insertion module.** The separator is formed in line and the cells are placed into the honeycomb pattern. Insertion is servo-controlled so the tray is presented square to the cartoner with every pocket filled. **Telescopic box forming machine.** Lid and base are formed from separate blanks and registered to each other. Both are formed on the same machine, which is what keeps the lid-to-base fit consistent across the six SKUs. **Box cartoning machine.** The filled honeycomb tray and the formed box are brought together, loaded in the correct orientation and closed. **Combined case opening and packing unit.** The shipper case is opened and the closed boxes are packed in one unit, so the line ends with a case ready to ship. **Recipe structure for three families.** Cell geometry, count per pack, honeycomb pattern, box size and case fill are all recipe parameters. Format changeover is 30 minutes, and it is the geometry differences — not the changeover mechanism — that set that time.