Case Study: Wraparound Case Packer Helps Virginia Artesian Meet Private-Label Packaging Demands

As beverage brands continue looking for ways to reduce packaging material and move away from plastic, secondary packaging plays a bigger role in the sustainability conversation.

For Virginia Artesian, Polypack built a custom WR-I Wraparound case former and filler designed to package aluminum water bottles in a streamlined, material-conscious format. The project brought together automation, corrugate efficiency, and a package style that supports a stronger environmental story.

Family-owned and operated since 2002, Virginia Artesian bottles premium water sourced from an underground aquifer beneath its Hanover, Virginia facility. The company serves private-label customers such as high-end hotels, resorts and golf clubs, where packaging requirements can vary from customer to customer.

With glass, PET and aluminum bottles in multiple sizes, Virginia Artesian needed an end-of-line system that could keep up.

The Challenge

Virginia Artesian needed a secondary packaging solution that could support the demands of private-label beverage production. Because much of the company’s business is built around private-label customers, flexibility was essential.

The system needed to handle multiple bottle materials and sizes, including glass, PET and aluminum bottles. It also needed to support different pack counts and case formats without creating long periods of downtime between runs.

Changeover speed was one of the most important requirements.

“Being able to go from one case size to another in less than 20 minutes is huge,” said Nick Brown, president of Virginia Artesian, in an article from Packaging World.

Sustainability was another major factor. Virginia Artesian had already invested in aluminum bottles as a premium, recyclable alternative to plastic. The next step was improving the secondary packaging around those bottles.

Some private-label customers were requesting corrugated secondary packaging instead of shrink wrap. By moving from plastic shrink wrap to corrugated cases made with recycled content, Virginia Artesian could better align its packaging line with its sustainability goals.

The Solution

https://www.youtube.com/watch?v=LrYpTWkMn84

Polypack supplied a Wraparound WR-I case former and filler  engineered to collate, stage, transfer and form corrugated packaging around Virginia Artesian’s bottle configurations.

The system was designed to support the flexibility required for private-label beverage production. It can handle multiple bottle formats and gives Virginia Artesian the ability to move quickly between packaging requirements.

In its current configuration, the system supports Virginia Artesian’s packaging needs while leaving room for future format changes. Box capability is built into the system for future products, giving the company additional flexibility as packaging demands evolve.

Virginia Artesian was already familiar with Polypack equipment before this project. The company had been running a Polypack shrink wrap machine since 2016, which helped build confidence in the relationship

“We’ve been running a Polypack shrink wrap machine since 2016, so we had that relationship already in place,” Nick Brown told Packaging World. “When you have that kind of experience with a machinery supplier and you know you can put your trust in the lines of communication, that makes things easier.”

How the Machine Works

The process begins as filled, capped and labeled bottles enter the Polypack case packer. The bottles are flood fed into the machine and guided into lanes for controlled product flow.

Once the correct number of bottles is in position, the product is staged into the desired pack pattern. The system can handle 12-count or 24-count configurations, depending on the production run.

A sweep arm transfers the grouped bottles onto a staging area. From there, a second sweep arm advances the bottles onto a corrugated blank.

The corrugated blanks are fed from a magazine. Vacuum cups pick each blank and place it into position on the lug conveyor. Once the product is loaded onto the blank, adhesive is applied to the flaps and the case moves through the forming and compression sections.

After the flaps are closed and the package is formed, the finished case exits the machine and moves downstream for coding, marking and additional handling.

The result is a streamlined wraparound case packing process that forms the package around the product instead of relying on a more material-heavy case style.

The Result

With the Polypack WR-I Wraparound case packer, Virginia Artesian gained a flexible end-of-line system built for the realities of private-label beverage production.

The system supports multiple bottle materials, multiple bottle sizes and quick changeovers between formats. According to Packaging World, Virginia Artesian runs 1-liter bottles at about 160 bottles per minute, with smaller bottles running slightly faster.

For Virginia Artesian, the biggest advantages are flexibility, changeover speed and the ability to support customer requests for corrugated packaging made with recycled content.

"We’d like to thank Polypack for taking on the challenge of packaging all 14 bottle sizes across multiple materials, including aluminum, glass, and PET, into a wide range of configurations. Their team approached the project with confidence and without hesitation. Throughout the build process, they remained flexible and responsive, accommodating late-stage changes driven by our final requirements. The entire experience reflected a true one-team approach and strong partnership." -Steve Brown, Co-Owner at Virginia Artesian Bottling Company

The system also helps the company move selected products away from shrink wrap and into corrugated secondary packaging, strengthening the connection between its recyclable aluminum bottles and its broader sustainability goals.

For private-label manufacturers, this project shows how the right end-of-line system can help production teams adapt to changing customer needs while supporting more efficient, material-conscious packaging.

Contact Polypack today to learn how a Wraparound case former and filler can help your operation reduce material use and package more sustainably.

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