Merge Systems

Kraken Merge Systems are designed to bring control to one of the most critical points in a packaging line: where multiple product streams need to become one. As part of a broader flow management and routing strategy, these systems do more than merge lances, they handle product timing, and overall downstream product flow with greater consistency.

Whether products arrive from parallel lanes, variable-speed upstream equipment, or with inconsistent spacing conditions, Kraken merge solutions are designed to stage, meter, and combine product flow in a way that supports reliable downstream performance. These systems help create a more controlled transition from multi-lane infeed to a single downstream process.

Controlled Product Release

These systems are commonly used ahead of cartoners, case packers, robotic loading systems, and other downstream packaging processes, where timing, spacing, and lane balance directly affect throughput and reliability.

Kraken Merge solutions are not off-the-shelf conveyor sections. They are integrated flow control systems designed around the realities of your line, your product, and your production goals

We help manufacturers improve:

Successful merging depends on more than simply bringing lanes together. Products must be released, timed, and presented in a way that prevents collisions, misfeeds, and disruptions.

Throughput Protection – When merge points are not smoothly optimized, they become bottlenecks. Kraken systems are designed to maintain production rate while balancing product flow between lanes and downstream equipment.

Real Line Integration – Merge systems do not operate in isolation. Kraken designs every system to communicate with upstream and downstream equipment for coordinated startup, shutdown,
accumulation detection, and fault recovery.

Flexibility Under Changing Conditions – In many applications, product spacing, speed, and availability are not perfectly consistent. Kraken merge systems are built to respond dynamically to changing line conditions while keeping the product moving.

Built Around Your Layout – Floor space, operator and maintenance access, elevation changes, and surrounding equipment all matter. Merge systems are configured to fit the line as it exists—keeping real-world layout constraints in mind.

2 to 1 Merge Systems

2 to 1 Merge System with Accumulation

Common Merge Applications

Kraken merge systems can be configured to support a wide range of downstream packaging and product handling needs, including:

Multiple down to-1 lane merges
Multi-lane indexing and infeed systems
Product staging and metering into cartons or case packers
Metered product release into robotic loading systems
Flexible package and pouch merging
Bag-in-box product flow control
Applications requiring product buildup detection and recovery logic

These systems are especially effective when the product must move from parallel, inconsistent, or high-speed upstream flow into a single controlled downstream process.

Typical Product Types

Kraken merge solutions are commonly applied to:
Pouches, Tubes, Bags, Cartons, Flexible packages, Wrapped products, and other packaging formats requiring controlled downstream presentation.

Designed for Real Production Conditions

Kraken approaches merge systems as part of the
broader packaging system—not as a standalone
equipment.

That means every merge application is evaluated
in the context of:

Upstream product behavior
Downstream machine demand
Line speed requirements
Pack pattern needs
Recovery and fault conditions
Plant floor constraints

The result is a system that helps the entire line perform more reliably, not just one transfer point.

Video Products

Multi Lane Diverter & Merger System

Merge 2 to 1

Need Better Control Between Processes?

If lane timing, spacing, or product flow is limiting line performance, Kraken can help engineer a merge solution that supports reliable downstream packaging.

The Kraken Approach to Integration

Kraken does more than supply equipment—we coordinate the entire solution so your line operates as one seamless system. We integrate new and existing machines, design transfer and conveyor elements, align product handling, and synchronize controls from upstream to downstream. The goal isn’t just installation—it’s reliable, high-performance operation.

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