Cartoning & Shrink Wrapping｜ Facial Mask

Automatic Horizontal Cartoning Machine, CHS-120 (CE), Shrinkable Type Flow Wrapping Machine, PSA-200W, and Shrink Tunnel, AS-350, integrated with an automatic counting system and an inkjet printing system for Facial Mask Packaging Line.

How Can You Ensure Accurate Piece Counting, Efficient Cartoning, and Consistent Packaging Quality for Boxed Facial Masks?

Boxed facial mask packaging requires more than simply placing a specific number of mask pouches into a carton. The process also involves carton forming, product feeding, date and batch code printing, flow wrapping and shrinking. When producing 5-pack, 10-pack, or promotional multi-pack facial masks, manual counting and cartoning can easily result in missing pieces, extra pieces, duplicate counting, uneven product arrangement, or reduced packaging efficiency due to operator fatigue and frequent product changeovers.

In this project, a leading facial mask manufacturer required an automated packaging solution capable of accurately counting pouch masks, feeding them into cartons, printing production information, and completing the final package with POF shrink film.

Based on the pouch dimensions, product thickness, carton size, quantity per carton, printing position, production capacity, and available factory space, Benison integrated an automatic counting system, an intermittent horizontal cartoning machine, an inkjet coding device, a horizontal flow wrapper, and a shrink tunnel into one complete packaging line. This integrated solution reduces manual labor while improving counting accuracy, production efficiency, and overall packaging quality.

Why Are More Facial Mask Manufacturers Choosing an Integrated Packaging Line?

Traditional multi-station packaging requires operators to repeatedly transfer and organize products between workstations, increasing labor requirements while creating opportunities for counting errors, carton misalignment, inconsistent printing positions, and unstable packaging quality.

An integrated automated packaging line connects every packaging process into a continuous workflow, minimizing manual handling and production delays while improving line stability. It also provides greater flexibility for future product variations and carton size changes, helping manufacturers maintain consistent packaging quality across multiple product formats.

▍Packaging Challenges

This project focused on three major packaging challenges:

Accurate Counting for Every Carton： Facial mask pouches are thin and visually similar, making manual counting prone to missing or duplicate pieces during continuous operation. Production becomes even more complex when switching between different pack quantities or promotional configurations, increasing inspection and rework requirements.
Printing Production Information on Every Carton： After cartoning, each carton requires accurate printing of production dates, batch numbers, or traceability information before entering the shrink wrapping process.
Supporting Multiple Carton Sizes on One Production Line： Facial mask manufacturers often produce different pouch sizes, carton dimensions, and promotional packs. Packaging equipment should therefore accommodate both current products and future product developments. Proper line planning must consider pouch dimensions, stacking height, carton specifications, and equipment adjustment ranges to maximize production flexibility and long-term equipment utilization.

▍Benison's Packaging Solution

After evaluating the product characteristics, packaging requirements, shrink film specifications, and production environment, Benison configured the solution with the CHS-120 (CE) Intermittent Horizontal Cartoning Machine, PSA-200W Horizontal Flow Wrapper, AS-350 Shrink Tunnel, and POF shrink film to create a complete automated facial mask packaging line.

The integrated production line includes:

Automatic pouch counting system
Automatic inkjet coding for dates and batch numbers
Seamless integration between cartoning and flow wrapping

By connecting each packaging stage into one continuous workflow, manufacturers can complete counting, cartoning, coding, and shrink wrapping within a single production line, significantly improving packaging efficiency while delivering a cleaner, more professional package appearance.

How Does the Packaging Line Maintain Accurate Piece Counts in Every Carton?

After entering the production line, each facial mask pouch is automatically counted and grouped according to the preset quantity. Once the required number of pouches is reached, the complete bundle is transferred smoothly into the horizontal cartoning machine for automatic feeding. Compared with manual counting, the automated counting system significantly reduces counting errors caused by repetitive operations while maintaining a stable product feeding rhythm. The quantity per carton can also be adjusted to support different packaging formats on the same production line.

How Are Production Dates and Batch Codes Printed Accurately?

After cartoning and carton sealing, the cartons are conveyed directly to the inkjet coding station. The coding device automatically prints production dates, batch numbers, or other traceability information at the designated location on each carton. By integrating the cartoning machine with the inkjet printer, manufacturers can eliminate manual transfer to a separate coding station while maintaining consistent carton orientation and printing accuracy throughout production.

How Can Cartons Be Better Protected During Storage and Transportation?

During handling, warehousing, and distribution, paper cartons may be exposed to dust, moisture, friction, and impact. For cosmetic products such as facial masks, the appearance of the carton is an important part of the product's retail presentation. Damaged corners, scuffed surfaces, or loose packaging can negatively affect consumers' first impressions. This packaging solution uses POF shrink film to provide a clear, tight-fitting protective layer around the carton. The film offers excellent transparency while helping protect the package from dust, moisture, and tampering, allowing the original carton design and brand graphics to remain highly visible.

Packaging materials, film width, and film thickness are selected according to the facial mask dimensions, product weight, packaging style, and required protection level. With proper equipment configuration, the same packaging line can accommodate a variety of facial mask carton sizes and product specifications.

What Are the Advantages of This Packaging Line?

This solution integrates automatic counting, horizontal cartoning, inkjet coding, and shrink wrapping into one complete packaging process based on the product characteristics, carton specifications, quantity per carton, and production requirements.

Compared with conventional manual or multi-station operations, the integrated line reduces manual counting, product handling, and repetitive sorting while improving count accuracy and packaging consistency. It also minimizes packaging issues caused by product misalignment, carton positioning errors, or inconsistent feeding.

When manufacturers introduce new package configurations, such as 5-pack, 10-pack, or promotional carton sets, the equipment can be adjusted according to the product dimensions and packaging requirements, providing greater flexibility for future production.

The use of POF shrink film also delivers a clear, tightly wrapped package that protects cartons from dust, moisture, and transportation damage while preserving the product's visual appeal and brand image. Combined with the horizontal flow wrapper's H-seal line, the final package achieves a neat, premium appearance. The solution can also be customized according to product size, packaging speed, and production capacity to meet specific manufacturing requirements.

Suitable Applications

This automated solution for counting, cartoning, inkjet coding, and shrink wrapping is suitable not only for boxed facial masks, but also for a wide range of packaged products, including:

Cosmetics & Skincare: Facial masks, eye masks, neck masks, hand masks, foot masks, and sample pouches
Personal Care Products: Wet wipes, cleansing pads, makeup remover pads, and cleaning wipes
Medical & Healthcare Products: Dressings, patches, sheet-type healthcare products, and individually pouched items
Food & Beverage Products: Tea bags, drip coffee, seasoning sachets, and powdered products
Household Products: Heat packs, desiccants, cleaning tablets, and other multi-piece boxed products
Promotional Packs: Trial kits, gift sets, and fixed-quantity carton packages

Actual suitability should be evaluated according to product dimensions, weight, surface characteristics, packaging materials, and production requirements.

▍Frequently Asked Questions (FAQ)

Can the number of facial masks per carton be adjusted? Yes. The automatic counting system can be configured to accommodate different pack quantities, such as 8-piece packs, multi-pack configurations, or other specified quantities. The available adjustment range depends on the pouch thickness, stacking height, carton dimensions, and equipment configuration.
Can the Same Packaging Line Handle Different Facial Mask Sizes? Yes. However, the product dimensions, pouch type, thickness, and carton specifications should be evaluated first. If the dimensional differences fall within the machine's adjustment range, production can be switched by changing machine settings or making simple mechanical adjustments. Larger size variations may require replacement tooling or customized modifications.
Is POF Shrink Film Suitable for Facial Mask and Cosmetic Packaging? Yes. POF shrink film is widely used for transparent overwrapping of cosmetic products, paper cartons, personal care products, and various consumer goods. In this solution, POF shrink film is selected for its excellent clarity, toughness, and shrink wrapping performance. The most suitable film specification should still be determined through testing based on the product dimensions and packaging requirements.
Can Only Part of the Packaging Line Be Installed? Yes. The solution can be configured according to the customer's existing equipment and production process. Manufacturers may implement a complete automated packaging line or integrate only selected modules, such as cartoning with inkjet coding, or connecting an existing counting system to a new downstream packaging line.

▍Machine Features & Specifications

Intermittent Horizontal Cartoning Machine, CHS-120 (CE) and Horizontal Flow Wrapper, PSA-200W

The intermittent horizontal cartoning machine has 3-axis servo control system for stable and precise operation.
Stainless steel construction for easy cleaning and excellent corrosion resistance.
Applicable box type: Flat tap, gluing seal & one-touch.
Multiple rejection mechanisms help minimize defective products.
The horizontal flow wrapper features a precision forming box and stable pusher feeding system to ensure consistent bag length and smooth product handling.
Tight shrink wrapping with a H-seal line enhances overall package appearance.
Reduced material waste helps lower long-term operating costs.
Easy maintenance and high machine reliability minimize downtime and maximize production efficiency.
Combined with POF shrink film, the package achieves excellent clarity, a tight shrink finish, and an enhanced brand presentation.
Equipment configuration, packaging materials, and production capacity can be customized according to actual manufacturing requirements.
Benison also provides production line layout planning, workflow optimization, and manpower planning services to help maximize operational efficiency.

Packaging Capacity	Max. 60 boxes per minute (depending on product size)
Output	Cartoning, Printing, and Flow Wrapping

How To Get A Solution Proposal?

The dimensions and thickness of the facial mask pouch, the number of pouches per carton, carton size, printing requirements, production speed, and available factory space all influence the design of the counting system, cartoning equipment, inkjet coding position, and shrink wrapping process.

Benison provides a complete one-stop packaging solution, including product evaluation, sample testing, packaging material selection, standalone machine recommendations, complete packaging line integration, on-site installation, and after-sales technical support. Our engineering team develops automated boxed facial mask packaging solutions tailored to your actual production requirements.

If you are planning a new packaging line or upgrading an existing one, simply provide your product dimensions, product weight, packaging requirements, and expected production capacity. Benison will evaluate the most suitable packaging solution based on your products and manufacturing conditions. Contact us through the inquiry form below or speak directly with our packaging specialists to discuss your application and packaging challenges.