Gaylord Box Assembly Vacuum Lift Assist Case Study

Large corrugated Gaylord cartons weighing approximately 40 pounds required two operators to lift, assemble, rotate, and position. Ergonomic Partners developed custom vacuum tooling integrated with a Gorbel Easy Arm so one operator could perform the handling and assembly sequence.

Vacuum Gripper to Lift, Pitch, Open and Flip Boxes

See the custom vacuum gripper lift, pitch, open, and rotate the Gaylord box through the assembly sequence.

Application: Assemble large corrugated Gaylord containers from flat cartons and position the completed boxes for the next production step.

Problem: The customer used two operators to assemble 40-pound Gaylord boxes by hand. The flat cartons measured approximately 5 feet tall by 4 feet long, making them bulky for one operator to lift and control. Operators handled the cartons approximately 10–12 times per hour, and a second operator was not always available.

Requirement: Pick up the flat carton, pitch it 90 degrees to vertical, open the box so the operator could fold and attach the flaps, then rotate the assembled box 180 degrees and set it onto a pallet.

Solution: Ergonomic Partners developed a custom vacuum lifting tool with grip, pitch, and rotate functions, powered by plant air. Venturi vacuum pumps provide the gripping force, while pneumatic cylinders control pitching and rotation. The tooling was integrated with a Gorbel Easy Arm to support the carton throughout the handling sequence.

Because pickup height varied from the floor to approximately 50 inches, a floating handle was incorporated to keep the operator controls within a practical working range. The system also includes an interlocked gripping circuit intended to prevent release while the carton is suspended.

Result: The completed system allows one operator to perform the carton lifting, pitching, opening, rotating, and positioning sequence that previously relied on two people.