What causes fault code PKG-CARTON1 (Cartoner — Product Insert Fault / Empty Carton)?

Product feed not synchronized with carton — product arrived late or not at all. Product pusher mechanism failed — cylinder not extending to push product into carton. Product jammed in the feed chute — stuck or oriented incorrectly. Carton was not fully opened — partially collapsed carton prevented product entry. Verification sensor failed — not correctly detecting product inside carton

How do I fix fault code PKG-CARTON1?

Clear the jammed or empty carton from the machine. Check product feed — verify products are arriving at the insertion point consistently. Check pusher cylinder operation — manually trigger and observe full extension. Inspect product feed chute for obstructions or misoriented products. Verify carton opening mechanism — vacuum cups, guide rails, and plows must open carton fully. Check insert verification sensor — typically a photo-eye or proximity sensor inside the carton station

Cartoner — Product Insert Fault / Empty Carton

PKG-CARTON1

Cartoning machine detected an empty carton (no product insert) or product not fully inserted into the carton. Machine stopped to prevent shipping empty packages.

medium packaging

packaging cartoner insert empty carton pusher verification

Probable Causes (ranked)

Product feed not synchronized with carton — product arrived late or not at all
Product pusher mechanism failed — cylinder not extending to push product into carton
Product jammed in the feed chute — stuck or oriented incorrectly
Carton was not fully opened — partially collapsed carton prevented product entry
Verification sensor failed — not correctly detecting product inside carton

Fix Steps

1 Clear the jammed or empty carton from the machine
2 Check product feed — verify products are arriving at the insertion point consistently
3 Check pusher cylinder operation — manually trigger and observe full extension
4 Inspect product feed chute for obstructions or misoriented products
5 Verify carton opening mechanism — vacuum cups, guide rails, and plows must open carton fully
6 Check insert verification sensor — typically a photo-eye or proximity sensor inside the carton station

Field Trick

When a cartoner starts producing empty cartons intermittently, watch the product infeed belt-to-bucket timing. Product is probably arriving at the bucket 50ms late, so the bucket is in position but the product hasn't dropped in yet. Adjust the infeed belt speed or the product release timing by small increments.

Suggested Replacement Parts

Parts matched to fault category: Solenoid Valve

SMC SY3120 Solenoid Valve P/N: SY3120-5LZD-M5 5/2 way, 24VDC, M5 ports, direct piping, 0.15-0.7 MPa

AutomationDirect $32.00 Amazon $28.00 McMaster-Carr $45.00 Grainger $42.00

Festo VUVG Solenoid Valve P/N: VUVG-LK14-M52-AT-G18-1R8L 5/2 way, 24VDC, G1/8 ports, spring return

AutomationDirect $55.00 Amazon $62.00 Grainger $70.00

Air Pressure Regulator + Filter Combo P/N: AW30-03BG SMC AW series, 3/8 NPT, 5-125 PSI, with gauge and bowl guard

AutomationDirect $38.00 Amazon $32.00 McMaster-Carr $48.00

Prices are estimates. Verify part numbers match your equipment before ordering.

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