Modular Precision in Motion: An Automated Cartoning Machine Adapts to Multiple Formats

The development of the Somic 434 SuperFlex packaging machine began with a simple premise: understand every motion the product must make inside the machine, then design the system around those needs.

Building on the broader Somic 434 platform, the 434 SuperFlex made its trade show debut at Pack Expo Las Vegas 2025, where it operated like a synchronized series of motions.

Peter Fox, CEO, Somic Packaging, Inc., who availed himself for media and customer demonstrations, said he doesn’t view the SuperFlex “as a custom machine, per se, but as a custom configuration.”

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The machine features a hygienic stainless-steel frame, fast format changeovers enabled by Somic’s pre-specified format range known as QuickChange, that allows additional formats to be operated on the same machine, and the option to incorporate Somic’s Coras planar (a collating and grouping  carrier system) for fully flexible, 360-deg. product orientation. This means that any number of additional formats can be operated later.

“The way we arrived at this system was to first lay out everything that needed to happen inside the machine,” said Fox, who also shared that the design concept of the 434 SuperFlex was borne from a partnership between Minnesota-based Somic Packaging, Inc. Somic Packaging and Kansas City-based Weber Inc. The pair laid out the groundwork for the machine about four years ago.

Built to Last: Manageable, Synchronized Modules

Somic’s engineers mapped out each step, from product pick-up and reorientation to final collation in order to examine the strengths and shortcomings of earlier designs.

Predecessor systems had relied on in-machine rotation or upstream reorientation to change product orientation, explained Fox. While functional, those methods offered limited control and introduced potential failure points. Turning a pouch during motion, for instance, could generate lateral forces that risk product slippage or drops. Moreover, the added weight of servo motors mounted on rotating portals led to premature wear on bearings and mechanical assemblies over time.

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The 434 SuperFlex reconsiders that architecture entirely. Rather than concentrating multiple functions in a single heavy module, engineers decomposed the motion sequence into discrete, intelligently coordinated subsystems. Each axis is managed independently yet synchronizes with the rest of the machine.

“It was really an effort of saying, let’s break every little piece out and manage each separately, but in concert with everything else that’s happening,” Fox said.

Separate but Connected: Decentralized Control Systems

Decentralized control systems are the core of Somic’s automation. “This machine has 57 servo drives in it, and each one of those servos has the drive mounted right on the back of the motor itself, which makes the whole layout so much simpler,” said Fox. “We’re using the Schneider control system. And you’ll see a lot of junction boxes located throughout the machine. That reduces the amount of cable that we need to use, and it makes for much easier troubleshooting. If you have an issue with the servo, it’s easy to remove that cable. So, it really streamlines the whole system.”

The system uses 57 servo drives with decentralized control, including a vacuum belt for product positioning and a lamella chain for product orientation. It can handle up to 38 pouches per case, with two bucket systems for efficient packing.

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Another key innovation, according to Fox, was the adoption of a linear shuttle system in place of the traditional integrated collection chain with built-in buckets.

“Originally, we were thinking about using our typical collection chain,” recalled Fox. “We basically would have a collection chain that would have the buckets integrated into that chain.”

But the problem with that, Fox explained, was that the earlier chain-based design introduced drag and mechanical load (getting more drag on the product), particularly under high throughput. The decision to separate the shuttling motion from the main transport path has resulted in smoother operation, reduces inertia and wear, and enhances long-term precision. The overall result has been a lightweight, modular handling concept.

“Going to a linear shuttle system really was the ideal solution,” he said.

Configured to Order: Flexible Packaging for High-Mix Production

Fox noted the modular design allows for seamless integration of additional functionalities, such as cover applicators or specialized handling modules. If specific product orientation is not required, sections of the machine can be omitted. This adaptive feature makes the machine suitable for a wide range of packaging tasks.

The Somic 434 SuperFlex is engineered for high-mix production environments, offering versatility in packaging various products (such as stand-up pouches, pillow pouches, folding boxes, cans, jars and blisters) into shelf-ready cartons.

Building on the broader Somic 434 platform, the machine’s adaptability, performance and flexibility earned it the nickname “SuperFlex” during the development with Weber and was embraced by Somic as the official name for this model.