In today’s fast-paced and competitive manufacturing and distribution environments, uptime is king, precision is non-negotiable, and efficiency is the name of the game. One piece of equipment that plays a pivotal—though often overlooked—role in this puzzle is the case erector.
But not all case erectors are created equal. The difference between a good line and a great one often comes down to one critical feature: total control.
What Is a Total Control System?
The Total Control System (TCS) is an advanced feature built into select Lantech case erectors. It ensures that each case is positively and securely controlled throughout the entire forming process—from blank separation and opening to folding and sealing. Instead of relying on gravity or compressed air to manage partially erected cases (which can result in jams, misfolds, or downtime), TCS uses mechanical and servo-driven elements to maintain 100% control of the case until it exits the machine, fully formed and sealed.
Total Control System — Precision, Reliability, and Efficiency
Lantech’s Total Control System powers their case, tray, and lid handling equipment, enabling delivery of perfectly square packages. This system counters common carton handling challenges and ensures smooth formation and sealing with minimal downtime.
Key Benefits & Performance Highlights
- Minimized Downtime: Rapid changeover between case sizes, fewer jams, and reliable operation simplify production flow.
- Reduced Waste: Capable of overcoming variations in blank quality, the system helps ensure consistent use of blanks—even those with minor defects.
- Flawless Square Cases: Produces cases with perfect 90° angles and vertical sides—critical for optimized stacking, packing, and shipping durability.
Core Components of the Total Control System
The system features a proactive, five-component architecture where blanks are pulled into place rather than force-fed, enhancing control and efficiency.
- Blank Delivery Control System
Utilizes powered infeed belts in the magazine to regulate blank delivery speed to the pick-up arm—preventing jams from early misfeeds and offering ergonomic, walk-in loading. - Blank Separation System
Employs multiple separation retainers to space blanks correctly, ensuring a vertical feed, one blank at a time—always synced with the pick-up arm’s readiness. - Square Case Delivery System
Features a hinged pick-up frame outfitted with eight vacuum-powered suction cups that grip two panels firmly, forming the case at a perfect 90° angle as the flaps are folded and secured. - Stationary Flap Folders & Pusher Bar
Flaps are folded while the case is immobile, and a single pusher bar slides the squared case into exit belts—retaining perfect angles and reducing mechanical stress. - Spring-Loaded Side Belts
Dual-side exit belts are spring-loaded and motor-synchronized to adapt to width variations, guiding the case while preserving the square shape without crushing it.
Why Does Total Control Matter?
Fewer Jams, More Uptime
Case jams are one of the most common and costly sources of downtime in a packaging line. TCS eliminates the uncertainty of free-falling cases or unreliable vacuum systems by physically guiding the case through every motion. The result? Significantly reduced jams and fewer manual interventions.
Perfectly Square Cases
Square cases matter. They stack better, protect products more effectively, and are easier to palletize. With Total Control, each case is handled gently and precisely, ensuring consistent 90-degree corners—without crushed flaps or bulging sides.
Better Sealing Integrity
Flap folding and tape application are only as good as the case presentation allows. When the case is square and stationary, the tape is applied evenly and securely. This prevents seal failures that lead to rework, damaged goods, or failed deliveries.
Flexibility with Case Styles and Materials
Whether you’re working with thin corrugate, recycled board, or challenging case dimensions, TCS accommodates a wide range of materials and box sizes. That flexibility helps operations scale and adapt quickly—without needing to manually tweak the machine between batches.
Comparative Performance: With vs. Without the Total Control System
| Key Parameter | Without Total Control System | With Lantech Total Control System |
| Case Squareness Accuracy | ±5–7 mm deviation typical | ±1 mm or less (consistently) |
| Unplanned Downtime (per 1,000 cases) | 4–6 incidents (jam, skew, misfold) | <1 incident (99.9% uptime rate) |
| Blank Jam Rate | Up to 8% on lower-quality blanks | <0.5% even with poor-quality materials |
| Changeover Time (avg.) | 20–30 minutes | Under 5 minutes |
| Stacking Strength Loss from Poor Cases | Up to 30% loss (non-square cases) | <5% loss due to perfect squareness |
| Labor Interventions (per shift) | 6–8 manual corrections/jam clears | Typically zero |
| Waste/Rejected Cases | 3–5% of output | Less than 0.5% |
Real-World Impact
Let’s say you’re running a high-volume food distribution center. You process thousands of cases per day, and every case jam adds up to minutes of lost production. With a traditional erector, a single jam every 10 minutes can result in hours of lost uptime each week. Multiply that across a year, and you’re talking tens of thousands of dollars in lost productivity.
Now imagine a system that virtually eliminates those jams. That’s what Total Control delivers—not just speed, but consistency, reliability, and peace of mind.
Who Benefits Most from Total Control?
- Operations Managers who are looking to reduce downtime and labor costs
- Packaging Engineers who need precision to maintain packaging integrity
- Distribution Centers where throughput and stacking accuracy are vital
- Facilities with fluctuating box types or recycled corrugate that demand flexibility
Bottom Line
Case erectors with Total Control Systems don’t just fold boxes—they create stability in your production line. They offer a smarter way to automate one of the most fundamental parts of your packaging operation and eliminate the chronic problems that cost time and money.
If you’re serious about packaging performance, it’s time to take control—Total Control.
Curious how a case erector could transform your operation? Contact us or explore our buying guide to find the right solution for your line.
