A modular case system and method of use provide for a case former having a base, interchangeable case gages and forming heads. Contained within the interior of the base are slide blocks mounted on slide rails and assemblies in such a manner as to allow the slide blocks to be slidingly reconfigured to form a case forming cavity of varicose sizes and shapes. The size and shape of the case forming cavity is established and maintained by a template opening, defined by, and potentially unique to, each case gage. The size and shape of the forming head corresponds to the size and shape of the template opening. The slide blocks are secured to the case gage by removable locking pins.

A locking receiving portion is defined by a first inclined line extending toward a third panel side on a first panel from a branching point on a fold line between the first panel and a second panel, a second inclined line extending toward the third panel side on the second panel from the branching point, and a cut portion extending between a distal end of the first inclined line and a distal end of the second inclined line. The locking receiving portion extends in an inclined manner between the first panel and the second panel in an assembled state. A locking portion is formed on the third panel, and configured to be locked to a cut portion side of the locking receiving portion in an assembled state.

A carton forming machine includes a carton blank push up device that receives a substantially horizontal folded carton blank and reorients the folded carton blank from the substantially horizontal orientation to an upright orientation below and in a first direction alignment with a carton opening mechanism. A carton blank positioning apparatus shifts the upright folded carton blank in a second direction, transverse to the first direction, below the carton opening mechanism to define a second direction position of the upright carton blank below the carton opening mechanism before the carton opening mechanism engages the upright carton blank for opening of the upright carton blank.

A bulk bin forming system configured as a container forming cell includes a multi-axis robot to which is attached a multifunction tool. One or more collapsed card board boxes are located at a first station of the container forming cell adjacent the robot. The robot and multifunction tool are configured to operate to grasp and move an individual box, orient and pre-form the box by folding flaps at a second station of the cell, and then move the box to a third station of the cell to mount the box to a support configured as a pallet to thereby form a bulk bin or bulk box container referred to as a gaylord container. The tool may include vacuum grippers for grasping the boxes and staplers for securing the formed box to the pallet, and may also be used to fold the bottom flaps prior to mounting the box to the pallet.

An apparatus and method for expanding a box blank into a box, the apparatus comprising an arm assembly, a controller, a camera and a box blank conveyor. The arm assembly includes a folding arm having a position in a first direction and a rotational angle controlled by the controller based on a position of a feature of the box blank in the field of view of the camera. The camera captures images of the box blank which are used to position the arm assembly and to evaluate the need to reject a box blank.