Abstract: To achieve higher efficiency and better packing quality in packing cigarette cartons of special size, a ZB45 cigarette packing line was modified to replace manual cartoning by improving packets collation, recalculating the transmission ratio, and designing new elevator and discharge pusher. Through motion simulation and on-site test, the modified packing line was tested with cigarette brand "Youxi" in China Tobacco Guangdong Industrial Limited Corporation, the results showed that:1) The movement of the pusher satisfied the design requirements; the maximum pressure angle 45.14° of the pusher cam and the curvature radius(10 mm) of cam were design specification compliant. 2) The packing line ran smoothly with the average noise level of 82.1 dB, the effective running efficiency was 89.4% and the qualified rate of packing reached 100%, which all met the requirements of relative standards. This technology provides a support for promoting the adaptability of packing lines.