If you are an internet retailer, you will be no stranger to the challenges that peak seasons bring.

During busy times like holidays or promotions, being able to process orders quickly is crucial for your business’s success. One of the critical components of managing this surge is your packaging process. This is where quick-install packaging machinery comes into play.

One way to streamline the packing process and boost efficiency is by implementing packaging automation. Fully integrated packaging automation takes a lot of time and planning. What we are focusing on in this article are quick and easy semi-automatic installations that are plug and play – simply set up where needed and remove some of the manual interventions needed when packing your products. The machines we will discuss will help make your operation more efficient and getting your shipments out of the door quickly during the busiest quarter of the year.

Quick-install packaging machinery provides an ideal solution for businesses looking to streamline their operations without the downtime associated with traditional fully integrated packaging automation and systems.

In this blog, we will focus on three key types of packaging automation that are easy to install, along with the benefits of each.  We also provide a checklist to help you prepare your business for automation.

Why choose packaging automation for e-commerce?

Automating your packaging processes can significantly enhance your packing operations.

One of the primary benefits of automated packaging systems is the cost savings and efficiency improvements they bring. Automation reduces labour costs and minimises human errors. Machines handle high order volumes, ensuring quick and accurate packaging, even during peak periods.

Automated packaging systems streamline order processing and packaging applications, enabling you to meet tight delivery deadlines. Improved turnaround times exceed customer expectations, resulting in positive reviews and repeat business.

What is the difference between semi-automatic and fully automatic systems?

Packaging automation is available with semi-automatic or fully automatic capabilities, which determines how much manual intervention is required by operators.

Semi-automatic systems involve a part-manual and part-automated process. For example, a box may be assembled and packed by the operator, but the machine will seal the pack.

A fully automatic packaging system will complete the task from start to finish. For example, assembling a box, adding void fill then sealing.

1. Box sealing

There are a few options available to ramp up the automatic sealing of your parcels.  Manually applying tape to your boxes can take up to 60% of your overall packing time when using traditional shipper cartons. 

The entry level quick-install step is to switch to a programmable electronic tape dispenser and water-activated tape.  These produce ready-cut lengths of tape at the touch of a button, removing the need to apply and tear the tape with a manual handheld dispenser.  Electronic Water activated tape dispensers are available either in a static workbench format, like the BP555 or, an on-the-go handheld device that can be used throughout the warehouse, like the Grip Taper. 

It’s worth noting that water-activated tape forms a stronger bond with corrugated material too. Therefore, the finished box is tamper-evident and easily recycled!

Some benefits of automated case sealers are:

Speed: Speeds up the sealing process by up to 60%.

Material savings: Dispenses the exact amount needed each time, reducing cost and material waste.

Versatility: Programmable so it can be configured to your in-house box range.

2. Void fill systems

Automated void fill systems use air pillows or paper to protect products during shipping by filling empty spaces in packaging. These are perfect for businesses that ship delicate or oddly shaped items and want to make sure they arrive safely.

Void fill systems for airbags are available with a small footprint, so they can be easily installed on a pack bench to dispense void fill materials at the touch of a button – or foot pedal.  Systems like the Mini Pak’r® or Pro Pak’R® offer recycled content airbag film too – so it’s a win for you and the environment.

Paper systems can be desk mounted or, height adjusted to stand behind the pack bench, this means it can dispense void fill materials directly into the box.  A good example of this in action are the Ranpak FillPak® systems.

Some benefits of automated void fill systems are:

Damage Reduction: Minimises product movement within the box, reducing the risk of damage.

Speed: Quickly fills voids, keeping the packaging process fast and efficient.

Material Savings: Optimises the amount of filler used, reducing waste and costs.

3. Pallet wrapper machines

Semi-automatic stretch wrap machines wrap products or pallets in stretch film to secure them for shipping. They are perfect for retailers who ship large amounts of goods on pallets to distribution centres or even direct to customers.

The system wraps the pallet automatically, leaving the operator free to prepare the next pallet for wrapping.

The benefits of an automated stretch wrapper are:

Stability: Provides additional stability to pallets, reducing the risk of products shifting or falling during transit.

Protection: Offers a layer of protection against dust, dirt, and moisture.

Efficiency: Reduces the amount of stretch film used, limiting material costs and waste.

How to select and install the best packaging automation for your business

To maximise the benefits of quick-install packaging machinery, we have pulled together a short checklist to ensure installation success.

1. Assess your current packaging process:

Identify bottlenecks and areas where automation can provide the most benefits. Consider factors such as packaging volume, product types, and available space.

2. Choose the right machinery:

Select machinery that fits your specific needs. Consider the types of products you package, the volume of orders, and the layout of your packaging area.

3. Plan the installation:

For quick-install machinery, planning is minimal. However, if you want to install more integrated systems, you will need to develop a detailed plan.  This should include timelines, responsibilities, and contingency plans to address potential issues.

4. Train your staff:

Make sure your team knows how to operate the new machinery. This training should cover setup, operation, maintenance, and troubleshooting.

5. Test and optimise:

After installation, run tests to ensure the machinery is functioning correctly. Monitor performance and make any necessary adjustments to optimise efficiency.

Quick-install packaging machinery offers internet retailers a powerful tool to prepare for peak seasons. These machines can enhance your packaging operations by increasing efficiency and quality. They can help you meet higher demand without compromising customer satisfaction. The machines are capable of quickly expanding and improving your packaging processes.

At Macfarlane Packaging, we can help you to identify and install the right packaging automation to improve efficiency. Contact us today!

The post 3 quick-install packaging automation systems for ecommerce appeared first on Macfarlane Packaging.

This has left many companies struggling to recruit and retain warehouse operatives against a backdrop of rising wage costs.

An efficient supply chain is reliant on warehouse staff to keep goods moving. Currently, many logistics operations are challenged to recruit a team of people to make that magic happen.

Businesses must find ways to address the labour shortage in a competitive job market. This is necessary to keep their logistics running smoothly. Packaging automation could be one such solution to help ease the tension of these labour shortages.

Why does the UK logistics industry have a labour shortage?

The UK has been going through changes in recent years, especially after Brexit. This has affected the logistics industry, which traditionally depended heavily on workers from the EU. During the Covid years, older workers, across many industries, made life-changing decisions to retire early. These factors have narrowed the pool of skilled labour available to employers.

The impact of labour shortages on warehouse operations

Businesses are offering higher wages to attract and retain warehouse staff. This is because there is a shortage of workers in the competitive labour market, driving up business costs and impacting margin.

If there are no staff available, it will affect how quickly products can be picked, packed and shipped out. This can lead to supply chain disruptions, delayed shipments and strained customer relationships. This may cause current team members to work extra hours, leading to mistakes, health and safety problems and damage to products.

What is packaging automation?

Packaging automation is a system which applies packaging consistently, with minimal operator intervention. There are machines that can tape, wrap, box, and bag items automatically, making the process easier and more efficient.

Automated packaging systems are ideal for high demand packing environments where speed and efficiency are key. If you’re shipping a range of differently shaped products in significant volume, the right packaging machinery and processes can help you to optimise your operation, cut costs and future-proof your production line for growth.

How packaging automation can help

Packaging automation offers an opportunity to reduce the challenges of labour shortages, supporting packing efficiency and enabling businesses to remain competitive. Packaging automation will:

Increase Efficiency and Productivity – as systems speed up the application of packaging. They can pack, seal, label and wrap products at high speed, quickly and accurately offering a consistent packing time.

Reduce Costs – through consistent packaging application, minimising material use as well as freeing up packers to do more useful tasks. For example, a stretch wrap machine will apply less stretch wrap with consistent tension, reduce packing time and free up the warehouse operator to go and fetch the next pallet to wrap.

As automated packaging systems use so much less material, return on investment can be a matter of weeks or months, depending on the initial outlay.

Reduce Damages and Returns – as packaging material is applied consistently and to a high standard, it reduces incidents of over and under packing and the potential of damages in transit.

Reduce Health and Safety Incidents – as warehouse operative tasks are often repetitive, packaging automation reduces pulls, strains and overstretching incidents as the machine completes the packing process.

Manage Spikes in Demand – as automated packaging solutions can be scaled up or down as appropriate. This reduces the challenges of hiring and training temporary staff during Peak season.

Types of packaging automation available

Packaging automation can take on a variety of forms, depending on your requirements.

A semi-automatic process is part manual and part automated. For example, an operator may start the process, but an automated packing system will finish it. This is typically a cheaper option if you are looking to introduce some automation but are working with a budget constraint.

A fully automatic packing process is programmed from the beginning to completion. This can include everything from picking, packaging application and palletisation for dispatch.

There are packaging automation solutions available for box building, tape application, holding product in place, void filling, bagging, strapping and applying stretch wrap.

Key considerations for implementing packaging automation

There is a range of solutions available for packaging automation from semi-automatic to fully automatic and integrated systems. The best choice for your business will be dependant on your business goals, the types of products you are packing and the size of your operation.

Before purchasing machinery, talk to a packaging automation expert who can help you determine how automation can benefit your operation and increase efficiency.

They can evaluate your warehouse layout and suggest ways to improve space, increase capacity, and efficiency. They can also help you to calculate a return on investment based on operating hours and packaging use. Often large investments in machinery can be daunting, however, there are rental schemes available for some systems.

By using packaging automation, your team can focus on more important tasks instead of repetitive ones.

Regular maintenance of automated systems is important to ensure they can operate at peak efficiency.

The UK logistics industry are facing a challenging labour shortage. However, using packaging automation can help improve operational efficiency, reduce costs, and minimise the use of packaging materials. This can help businesses succeed in the competitive job market and prepare for growth and seasonal increases in demand.

Learn more about packaging automation and available solutions by downloading our guide. It will help you find the best solution for your operation and reduce total cost. 

At Macfarlane Packaging, we help customers reduce costs and increase the efficiency of their packing operations through the successful integration of packaging automation. Contact us today to learn how we can help your business.

The post Managing labour shortages in logistic operations appeared first on Macfarlane Packaging.

The act of sealing parcels is often one of the most time-consuming parts of the packaging process. Therefore, automation can help to transform the way businesses approach this essential task. Using case sealers or gummed paper tape dispensers can quickly improve productivity.  It doesn’t have to break the bank either – there are options for a range of budgets.

In this blog, we will discuss case sealing and case sealing automation. We will talk about why it is important, the various types of equipment, and how it can affect your packing process.

Understanding Carton Sealing

Using tape to close a box is a simple part of packing, but it can be more complex than you think. The complexity of case sealing can vary depending on the type, amount and mode of application of the tape. This is especially true when done manually.

Sealing a cardboard box can consume 60% of your overall packing time.  Therefore, it’s a great area to review when you need to increase your productivity.

The Importance of Carton Sealing

Sealing is an important and time-consuming part of packing. It can also impact your pack security, costs and packaging waste if you’re not sealing the boxes effectively.

Too much tape, and you’re wasting packaging, increasing cost and often, producing an unsightly parcel. Not enough tape and you risk your parcel opening during shipping, leading to poor customer experience.

The type of adhesive you use for sealing is important too. For example, if you’re shipping in freezing conditions, you’d need to use an adhesive suitable for that. Some adhesives won’t work if they’re too cold!

The packing process can influence many of these important factors. Using automation can help you control costs, effective application and the amount of material used. Paired with the right tape and you’ve got a recipe for sealing success.

Different Types of Automatic Case Sealers & Tape Dispensers

Automatic tape dispensers and case sealers (also called carton sealers) can dispense and apply pre-set lengths of tape. They reduce packaging waste and significantly speed-up packing.  Some automatic case sealers also use glue rather than tape.

Here are the common types of carton-sealing automation:

• Electronic gummed paper tape dispensers – available as tabletop or portable dispensers, these machines dispense pre-set lengths of gummed paper tape. They’re often a good first step in sealing automation, as they’re relatively low-cost. The below video shows the Grip Taper: a portable gummed-paper tape dispenser.

• Self-adhesive tape case sealers – these machines will automatically seal your boxes using lengths of tape. Standard case sealers are usually pre-set to work with a specific size box or case format.

• Hot melt glue case sealers – working on the same principle as a self-adhesive tape case sealer that uses tape, this type of carton sealing equipment uses molten glue to seal boxes.

• Random case sealers – random case sealers can seal different sizes boxes and formats. They can use tape or glue as the sealing material. They’re suitable for operations where many different sizes and shapes of products are being packed. Here’s a video of a random case sealing machine that uses tape to seal the cartons.

How to Choose the Right Carton Sealing Equipment for Your Business

The carton sealing equipment you choose will depend on lots of factors. You should think about what you’re packing as well as your storage and shipping conditions. Your production goals, budget and warehouse space will also be important considerations too.

For smaller operations, gummed paper tape dispensers are a good first step. If you’re packing a higher volume of boxes, pre-set case sealers would be the logical next step. For high-capacity production lines with a range of pack sizes, random case sealers are an ideal choice.

Carton sealers and tape dispensers can be added to your packing line along with other automation like a case erector.

Ultimately, it’s worth taking advice from packaging automation experts. You can often get a recommendation that’s specific to your business.

How Automation Can Speed Up Case Sealing and Benefit Businesses

Speeding up carton-taping can be a big productivity win. Using a case sealing machine or automatic tape dispenser can be key to doing this. Let’s explore the benefits of automating your sealing process:   

How Automatic Case Sealers Can Improve Productivity

Automatic case sealers streamline the packing process. They drastically improve productivity with consistent, reliable results.

An automatic case sealer will automatically fold the top flaps on a box, dispense tape or glue and consistently seal it every time.  This not only improves overall productivity but also frees up manpower for more complex tasks.

Cost-Saving Benefits of Efficient Carton Sealing

Investing in automation may seem expensive at first, but the long-term advantages are worth the initial investment. Plus, there are lower-cost options like gummed paper tape dispensers that can work for smaller budgets.

In terms of cost-saving benefits of using a case sealer or electronic dispenser, key advantages are:

• Lower material costs – save money on tape by using the right amount of material each time, allowing you to monitor and control your spending on tape.
• Labour cost-savings – as the packing time is much quicker, your operators can manage increased throughput. You can also reduce the need for temporary staff during peak periods.
• Reduced damages and returns – secure, consistent sealing can reduce damages and returns. In turn, this lowers waste and costs associated with this process.

Investing in Carton Sealing Equipment: ROI and Benefits

Automating sealing using a case sealer or electronic dispenser saves money in so many ways. Because of this, the investment can often pay off in months rather than years.

To determine the ROI of sealing automation, consider both the machine’s upfront cost and the long-term savings it provides.

FAQs: Answering Your Carton Sealing Queries

What Are the Different Methods of Carton Sealing?

Lots of ways to seal a carton exist. The most common way is using self-adhesive tape and a manual tape dispenser.

Other ways include semi-automatic and fully automatic processes, such as gummed paper tape dispensers and the previously mentioned case sealers.

What Is a Carton Sealer?

A carton sealer is a machine designed to automate the process of sealing cartons or boxes. Also known as case sealers, they either apply tape or glue to a box to seal it.

There are various types of carton sealers, like random case sealers that can seal different sizes and formats of boxes.

How Does an Automatic Carton Sealer Work?

Automatic Carton sealers work by automatically folding the top flaps of a carton, applying adhesive materials such as tape or glue, and securely sealing the box. The process varies depending on the type of carton sealer, with manual, semi-automatic, and fully automatic options available.

Summary

There are sealing automation solutions to suit every size of business.  Whether you are looking for an integrated system for high volume shipments, or a semi-automatic solution to fit into a fledging packing operation.

Introducing a case sealer or electronic tape dispenser can help you significantly speed up carton sealing, saving you time and money.

When you have the right carton sealing solution, you can enhance productivity, reduce costs and ultimately deliver an improved customer experience.

To help make the right choice for business, get in touch with one of our packing automation experts today.

The post Using Automation to Speed Up Case Sealing appeared first on Macfarlane Packaging.

So, have you ever considered using a case erector? Also called a carton erector or auto carton erector, these advanced machines can improve how you deal with your cardboard boxes.

This article will explain what a case erector is. It will also discuss the various types of case erecting machines. Additionally, it will explain the benefits of using one in your production line.

What is a case erector?

A case erector is a type of packaging machinery designed to automatically erect and seal corrugated cardboard boxes. They can simplify the packing process and significantly improve productivity, especially when used alongside other packaging automation.

Also known as carton erectors, these machines efficiently erect various box sizes and styles (depending on the machine selected). They offer a versatile solution for businesses with diverse packaging needs.

Do not confuse case erectors with case sealers, machines that seal boxes with either packing tape or glue.

Types of case erectors

There are several different types of case and carton erectors available on the market. We separate them into three broad categories:

Semi-automatic case erectors

Semi-automatic carton erectors will automate part of your box erection. They require some manual intervention, typically in loading flat boxes into the system. Once loaded, the case erector automates the process of erecting and sealing the boxes.

Often, semi-automatic carton erectors can be a good first step for box automation. They can sometimes be used as a stand-alone machine, to help with easy packing, or paired with a case sealer.

Automatic case erectors

Fully automated, this type of carton erector performs the entire box assembly process without the need for manual input. Automated carton erectors often offer case sealers that can use glue or tape. They are highly efficient, reducing labour requirements and increasing overall productivity.

This type of erector is good for higher-demand environments. You can modify many high-spec automated carton erectors to suit operational requirements too.

See one of the models Macfarlane can supply in action

Random case erectors

Random carton erectors handle a variety of box sizes without needing adjustments. This type of erector is ideal for businesses dealing with a diverse range of products.

Both standard carton erectors and random carton erectors work with pre-formed corrugated cardboard boxes. For example, a FEFCO 0201 style box. Random carton erectors can erect different size and shape boxes.

 Right-size carton systems

In addition to the erectors mentioned, it’s also worth noting right-size carton systems. While they are technically not case erectors, they are a type of packaging automation associated with boxes.

A right-size carton system essentially builds the right-size box for a product. This can be from a continuous fanfold of corrugated material or tray style boxes that are reduced in height before a lid is glued on. They are also known as void-reduction systems, as they minimise the amount of empty space in the finished pack.

So, which type of case erector is best?

There are many different brands of case erectors on the market. The type of case erector that will be right for you will depend on several factors, such as what you’re packing and shipping, product weight, how the package will be stored and shipped, as well as your production environment.

Consulting with a packaging automation expert before investing in machinery like this is always worth it. It can help you choose a case erector that will deliver what you need for your business.

Depending on your business maturity, you might be ready for a case erector now. Alternatively, you might consider an interim solution like a box erecting frame before you progress to machinery. This video highlights signs you’re ready for packaging automation.

6 ways you can benefit from a case erector

Now you know what a case erector is and the different types available, how can a case erector benefit you? Here are six ways your business can benefit from a case erector:  

1. Speed and Efficiency

Automatic carton erectors drastically reduce the time and effort required for box assembly. Some models offer a 233% productivity increase compared to manual processes. Case erecting machines erect and seal boxes at a much faster rate than manual methods. This significantly boosts overall productivity.

2. Precision and Consistency

Manual processes come with the risk of human error. Case erectors ensure precise and consistent results when assembling cardboard boxes. This leads to improved product protection during transit and enhances the overall quality of your packaging. Plus, if you’re palletising your product, case erectors can provide square cases every time, which means they’re easier to stack as well.

3. Environmental Impact

The precision and consistency associated with a case erector can also reduce your environmental impact. Erectors eliminate waste that human error can produce, resulting in less waste to recycle or dispose of.

In addition, square cases every time can help manage your parcel cubage minimising CO₂ emissions during transport. Another eco-friendly benefit is reducing damages in transit. This is because it cuts out the potential emissions (and cost) associated with reverse logistics.

4. Enhanced Workplace Safety

Many manual processes, such as box assembly, packing and sealing, can lead to repetitive strain injuries and staff fatigue. By automating the box erecting process, case erectors contribute to a safer working environment by minimising physical strain on your team.

5. Improved Brand Image

Consistently well-packaged products contribute to a positive brand image. Using a case erector ensures that your boxes are neatly and professionally assembled – reflecting your brand image. This can be particularly important in the online retail sector, where packaging is often the first physical touchpoint with a business!  

6. Cost Savings

When you think about investing in a case erector (or any packaging machinery) cost savings might not be the first thing that comes to mind! However, while the initial investment in a case erector may seem substantial, the long-term cost savings are significant.

Due to the efficiencies offered by a case erector, you can reduce labour costs, including the need for temporary labour during peak times. Plus, you can often reduce the amount of packing material you’re using, which results in further savings.

In addition, your production throughout put can increase significantly, helping you keep up as your business grows. Ultimately, you can enjoy a more cost-effective packing process.

Summary

Introducing a case erector into your packaging line is an intelligent move that can pay dividends. Opting for automation will help you move towards efficiency, cost savings, and improved packing quality. If you leverage packaging automation, you will be better positioned to thrive in the competitive landscape and future-proof your packing operation.

So, if you need help with a case erector (or any packaging machinery), please speak with one of our experts today.

The post 6 ways you can benefit from a case erector appeared first on Macfarlane Packaging.

If you would like to increase productivity and shorten the time it takes to deliver products to customers, automated packaging systems and processes might be the answer.

With so many options available, you may be wondering which solution is the best for your operations. Don’t worry, we’ve got you covered!

In this blog article, we will define packaging automation, explore different types available and look at some of the key advantages and frequently asked questions related to packaging automation. Continue reading to find out more.

Packaging automation – what exactly is it?

Packaging automation entails introducing automated equipment and machinery into your packing operation to accelerate the packing process.

This helps to assure consistency, avoid material waste, and save money in the long run. It also enables you to reallocate valuable resources to high-value jobs or in the most efficient method for your operation. Most areas of the packaging process can be improved by introducing automated packaging systems; from picking and packing to conveying and wrapping, there are packaging machines for it all. 

What are the different types of packaging automation?

Erecting boxes, taping cartons, and wrapping pallets for shipment can all be automated. We distinguish between semi-automated and automated packing methods:

• A semi-automated packing process combines both human involvement with elements of automation. For example, an operator can start the process, but an automatic packing system will finish it. If you want to use automation but have a restricted budget, this is usually the most cost-effective option.
• An automated packing process is pre-programmed from start to end. It can handle everything from picking products, and packaging to palletising for shipping. This option is a good solution for operations where demand is high or that predict significant grow.  

We distinguish between the following automation solutions, based on the product you’re using:

• Box automation – including solutions, such as case and box erectors, fully and semi-automated auto boxing machines as well as void reduction systems
• Tape automation – e.g. semi and fully automatic tape dispensers, in-line taping machines and carton sealers
• Bag automation – e.g. automated bagging machines and bulk bagging equipment
• Protective automation – including semi and fully automated void fill machines, air cushioning and air pillow machines
• Paper automation – e.g. paper wrapping equipment, paper void fill machines and paper cushioning systems
• Strapping automation – solutions such as: semi and fully automated strapping machines, friction welders, battery powered strapping tools and banding tables  
• Stretch automation – e.g. fully and semi-automatic pallet wrappers, vertical and horizonal stretch wrapping machinesand rotating arm stretch wrap machines
• Polythene automation – e.g. shrink-wrapping machines,heat shrink tunnels, heat sealers, impulse heat sealers and vacuum packing machines
• Auxiliary equipment – solutions, such as: automated labelling equipment, case stackers, sorters, palletisers and conveyor systems

Key benefits of packaging automation

Packaging automation offers many benefits. It can help you to:

• Boost productivity, allowing you to pack more parcels in less time
• Save space, using fewer packaging SKUs and, therefore, saving storage space before parcels are packed (less packaging stored on site), as well as cubage, which saves transport space.
• Lower operating costs, resulting in savings on labour, storage, transportation, packing materials, and productivity
• Streamline workflow, ensuring your packaging process runs as smoothly as possible
• Reduce volume handling, relieving operational strain and helping better manage spikes in demand
• Assure pack optimisation and consistency, ensuring that the appropriate quantity and type of packaging is used every time
• Minimise material waste, making sure you only use the right amount of material required to protect your product during transit and avoiding overpacking
• Reduce transport and fuel costs, enabling you to pack more products onto a pallet. This will also help reduce your carbon footprint, as less fuel means fewer CO₂ emissions.
• Ensure customer satisfaction,providing smart, beautifully packaged parcelsthat arrive with your customers damage-free
• Future-proof for growth and demand, increasing your capacity and helping control costs as your business grows.  

Read our latest blog post – Automated packaging: 10 decisive benefits – to find out more about various benefits that comes with packaging automation.

Frequently asked questions about packaging automation

Below are some of the most frequently asked questions about packaging automation solutions, along with our answers. If there’s something you would like to learn more about that we haven’t covered below, please get in touch.

How do I automate my packing process?

There are many ways to automate your packing process. You can automate almost any part of it, but if you need pointers of where to start, you will need to review your packing operation first. This will help you identify any bottlenecks or processes that could be improved or automated.

Some of the common bottlenecks include:

• Picking accuracy – miss-picks can be a sign that something isn’t working or that capacity is being outstripped by demand.
• Packing times – have packing times met targets? Are packers taking longer to process orders? During high-pressure times, packing times can be a bottleneck if processes aren’t efficient and packing materials aren’t easy.
• Dispatch lead times – do your dispatch lead times keep increasing and getting longer? This can be in response to high demand, but it can also suggest that processes need to change.
• Damages – are customers reporting an increase in damages? This can be an indicator that packing isn’t being completed properly or that the packing materials being used aren’t sufficient. 

How to choose the right packaging machine equipment?

The type of automation solution you need will depend on your products, processes, productivity goals and space in your warehouse. You will also need to factor in your budget.

There are lots of different types of packaging machinery available, from cardboard box and case erectors and auto-bagging machines through to pallet wrappers, heat shrink tunnels, in-line taping machines and many more!

What will packaging automation cost me?

Packaging automation can be an investment, depending on the solution you’re looking at. There may be a large upfront cost to purchase an automated packaging system, but the money you’ll save elsewhere in your operation will counterbalance this in the long run.

Not every system requires an initial outlay – many are available for rental or can be purchased through finance agreements. A free trial is available on many machines, which gives you the opportunity to test if the solution is right for your business. Plus, there are some cost-effective automation options out there, such as water-activated gummed paper tape dispensers. You can also opt for semi-automatic machines that can be found at a lower price point.

How do I calculate return on investment (ROI) for packaging automation?

The ROI for packaging automation is calculated by comparing the costs associated with implementing automation to the benefits it brings, including cost savings and increased productivity.

When calculating the cost of automation for your business, there are several factors to consider, including your initial investment, equipment costs, installation setup fees, staff training, and any projected long-term costs, such as maintenance and repair. Then, think about how much money you can save each year with packaging automation. This can include reducing labour costs, increasing productivity and throughput, reducing material waste, as well as improving product quality and consistency.

How do I futureproof the investment in packaging automation?

When you invest in packaging automation, it’s important to make strategic decisions and put processes in place to keep your packaging automated system running smoothly and up to date with the latest technologies and industry developments. Consider things such as regular and preventative maintenance, staff training, periodic calibration and testing of equipment as well as spare parts inventory.

Why choose Macfarlane as your automation partner?

At Macfarlane Packaging, we work closely with our customers on a case-by-case basis to find the best automated packaging solutions for their requirements.

We can offer a wide choice of automated packaging solutions to fit various demands and budgets, whether you need a pallet wrapper, water activated tape dispenser, carton sealer, case erector, or anything in between.

Contact us today to go over your packaging needs.

The post Packaging automation: a quick guide    appeared first on Macfarlane Packaging.

In this article, we’ll give you an overview of packaging automaton, the types of packaging machinery available and show you 10 decisive benefits that automated packaging can offer.

What is packaging automation?

Packaging automation is when automated tools and packaging machinery is used to increase the speed of packing alongside manual processes. It ensures consistency, reduces material waste and helps generate cost savings in the long run.

Using automated packing systems allows you to reassign valuable resource to high value tasks or in a way that better suits your operation too. You can enhance most aspects of a packaging process; from picking and packing through to conveying and wrapping, there are packaging machines for it all. 

There are semi-automated and automatic solutions available for a range of applications and businesses of different sizes.

Types of packaging automation and machinery available

You can automate almost any part of the packing process. Popular types of automated packaging include:

• Box automation – you can automate case erection and case making with case erectors, helping you get a perfectly shaped box every time!
• Bag automation – if you’re bagging product, auto bagging machines are available to speed up production, including systems that run both paper and polythene bags.
• Tape automation – rapidly sealing boxes with a case sealer that uses machine tape or a gummed paper tape machine can help you process more packs per hour. 
• Stretch automation – using semi-automated pallet wrappers is a great solution for any business using more than 15 pallets per day. Fully automated and horizontal wrappers are available for high-demand operations too!
• Strapping automation – an extensive range of banding machines are available, from handheld welding tools through to fully automated strapping machines that apply pallet banding for you.
• Protective automation – easy to install into existing packing areas, inflatable air void fill machines and paper cushioning machines can be used to keep your products safe during transit.
• Paper automation – from wrapping through to void fill and cushioning, you can choose from a wide range of paper packaging machinery to enhance your operation.
• Polythene automation – heat shrink tunnels and heat sealers can make light work of bundling and packing products!

You can also automate picking and warehouse movement with robotics and conveyor networks.

10 decisive benefits of automated packaging

So, why should you think about upgrading to automated packaging? Here are 10 decisive benefits for you to consider:

1. Improved productivity – in most lean supply chains, time is of the essence. You want to get your product packed and out the door as quickly as possible. Enter automated packaging systems.  You can speed up your pack times exponentially! For example, some case sealers and auto bagging machines can produce up to 30 packs per minute!
2. Reduced downtime – implementing packaging automation can often mean less downtime. As many packaging machines have a large capacity, your team can often reduce the time spent fetching packaging or replenishing manual workstations. 
3. Control over labour costs and allocation – improving your productivity has a knock-on effect on your labour costs and allocation. Using packaging automation allows you to cut the need for temporary labour during peak periods and reallocate permanent resource to your most high-value tasks.
4. Enhanced health and safety – as packaging automation removes manual processes, it can have a positive influence on your staff health and safety! For example, it often lowers the risk of repetitive strain injuries or accidents associated with manually adjusting packaging (e.g. cutting boxes down with knives).  
5. Lower packaging waste and improved sustainability – using automated packaging can control how much material you use – this can help you lower packaging waste and improve your overall sustainability, as your pack size will be optimised throughout your supply chain.
6. Improved packaging process quality control – packaging automation can remove the element of human error. No more over or under packing, an automated packing system will use the right amount of material every time. You’ll get consistent pack size and appearance, as well as the above-mentioned reduced packaging waste!
7. Fewer damages – the improved packaging consistency can help you reduce damages that occur during shipping too, as your packaging is optimised every time.
8. Better parcel palletisation – consistently sized packs can help improve palletisation, you may be able to get more packs on a pallet or improve your pallet strength and durability via improved stacking.
9. Lower transport costs – the optimised packaging achieved through automation can help you control transport and courier costs. You may have lighter packs, improved cubage and better palletisation, which all have a positive knock-on effect.
10. Space released in your warehouse – in addition to the above benefits, using automated packaging systems can even save you space! Many machines have compact footprints and switching to automation may allow you to condense the packaging materials you keep in your warehouse, releasing valuable space for your product.

With these 10 benefits of packaging automation in mind, now might be the time for you to consider implementing it!

Support with packaging automation in 2024

At Macfarlane Packaging, we can help you transform your operation with packaging automaton. Click here to learn more about how we can help with automation or get in touch today to book some time with our automation experts.

The post Automated packaging: 10 decisive benefits appeared first on Macfarlane Packaging.

Resolutions don’t just happen in our personal lives either, it’s a great time to reflect on business performance in 2023 and what improvements you could put in place to make 2024 stronger. 

In our experience, a good place to start with workplace resolutions is your packing operation. Changes there can have a positive knock-on effect throughout your business – improving efficiency, reducing cost, maximising transportation, and reducing the carbon footprint of your supply chain.

Here are eight packing operation resolutions to consider for 2024:

Create space to grow your business

If you’re fast outgrowing your warehouse or, would like to expand your operation but cannot see the way to do this without moving a new premises, then perhaps a rethink of how you are currently utilising the space may help.

Warehouse space is at a premium and forms a large part of any company overhead, but have you planned that space or, has it just evolved over time to accommodate your operation?

A rethink of your storage space may unlock opportunities to expand production or your packing area. For example, a pallet stored on the floor takes up 1.2sq metres of space, often enough area to install a pack bench.

If your looking at ways to increase your workable space, you may be interested in reading our previous blog “How to unlock warehouse space for your packing operation in 2023”, it’s an oldie but goodie.

Identify opportunities to free up cashflow

Cashflow is king, so why are you paying invoices for bulk quantities of packaging which won’t be used for months? You may get a great price from a manufacturer initially but, packaging doesn’t generate revenue. The cost of storing slow moving stock week after week is cancelling out those procurement savings.

Consider buying little and often from a packaging distributor on a stock and drip contract or JIT. You get the packaging you need, when you need it and, paying for it at point of use.

Removing pallets and pallets of slow-moving packaging stock also contributes to your first resolution of creating more space too!

Boost efficiency with an ergonomic space

Is it time to rethink the layout of your packing operation? There are so many ways you can optimise a workspace to make it more efficient and increase productivity.

Well organised, purpose-built workstations can revolutionise the packing area, reducing the amount of “wandering” around the warehouse to get the right packaging to wrap products being shipped.

They can be customised to hold the packaging you need, including different sized boxes and mailers, protective infill systems, tape dispensers and label printers. With everything you need to hand, your packing area can become a well-oiled machine. 

Pack bench height can be adjusted too, allowing you to tailor the station to the comfort of your packers, so they can either sit or stand (don’t forget an anti-fatigue mat too, to reduce the risk of pressure to feet and legs).

Consider a conveyor system interconnecting picking areas, pack stations and goods-out. Creating a seamless link in your packing operation, they can be fixed or mobile, set to the height required for your products, and be as integrated or free standing as you require.  For example, you may go with a roller conveyor to start, where you manually push the goods to the next area.  For larger more established operations, a belt driven option with light sensor activation and control can be set to automatically direct packaging to multiple locations.

Reduce the amount of packaging material you use

When less packaging is used, you are not only reducing overall waste but business costs too.  It’s a win-win situation.  This is especially important if you are working towards the new EPR legislation which will affect manufacturers, distributors, and retailers where their product packaging will end up in household waste streams.

A rethink in box size can reduce the amount of material used as well as reducing the need to void fill. 

Are there opportunities to re-engineer your packaging material to reduce the weight? 

Consider ways to reduce the weight of material you’re using each year too. For example, a switch to a stronger adhesive tape can help to reduce the overall amount you need to apply, removing the need to H tape packs.  A stretch wrap review can also unlock opportunities to reduce the amount of material needed to wrap each pallet, often a Macfarlane Packaging Stretch Wrap Review reduces material use by up to 50%.

As well as reducing material use, you will also reduce the cost of your packaging and improve the overall carbon footprint of your business.

Optimise your delivery fleet and courier network

Building on the resolution of using less packaging material, by rethinking your packaging and optimising your pack cubage you may be able to fit more goods onto a pallet or, increase your vehicle payload. 

This will drive optimisation of your delivery fleet or reduce courier costs if you’re paying by size or weight of parcels shipped.

By increasing the capacity of your delivery vehicles, you can reduce the amount of vehicles you need to load, combat driver shortages and fluctuating fuel costs.

Combat labour shortages with packaging automation

Labour shortages are a defining feature of the logistics industry, but when you use packaging that’s quick to assemble, pack and wrap, you can increase throughput and manage production spikes more efficiently with the workforce you have in place.

Bringing in a level of packaging automation can also help to support a more efficient operation, reducing menial, repetitive tasks and allowing you to upskill your workforce.

There are packaging automation solutions for every size of business, at a cost to suit every budget too.  It doesn’t need to be a huge cap-ex project.

For smaller businesses, you may consider entry level automation, like electronic gummed paper tape dispensers, which cut strips to size ready for speedy application.  Or perhaps a void fill dispenser which automatically adds the right amount of protection at the click of a foot pedal.

If you’re wrapping more than 14 pallets per day, consider a stretch wrap machine which efficiently applies film to your pallets, leaving your operators free to take the last pallet to goods out or, bring in the next pallet for wrapping.

Box erectors and sealers can assemble your packs ready for filling, so operators can focus on packing. If you want to “go large” an auto-boxing or bagging machine can be installed to build, fill and seal packs.

Automation can be as integrated as you want to make it, there are options to suit every size of business to reduce the number of touches to a product or pack, reduce manual handling and material use, as well as speed up your operation. 

Meet your sustainability targets for 2024

Carbon footprint reduction plays a key part in ESG goals, with larger businesses committed to Mandatory Greenhouse Gas Reporting by the UK Government. The race is on to make better use of natural resources.

Many of the resolutions above will help you to reduce your packaging use, optimise your delivery fleet and cut emissions from the supply chain. 

Book a packaging review with Macfarlane Packaging

So, how do the above resolutions sound? Overwhelming when you still have your regular day job to do?  Don’t worry, we can do all the above for you with a free of charge, no obligation packaging review!

We come to, walk through your operation to see what your packing, how you’re packing it and then, we suggest some solutions to help you get those resolutions in place.

Look at how Macfarlane Packaging can support your business or, contact us today to book your packaging review.

The post 8 packing operation resolutions for 2024 appeared first on Macfarlane Packaging.

Increased demand presents both challenges and opportunities. It can often highlight what works well and what doesn’t in a bustling warehouse environment. As we work through peak and look ahead to 2024, it’s a good time to reflect on bottlenecks in your operation.  

In this article, we’ll look at the ways you can identify bottlenecks and common challenges in packing areas. We’ll also discuss solutions to streamline your warehouse packing operation and how you can improve your warehouse productivity.  

Ways to identify bottlenecks in your warehouse  

There are lots of ways you can identify pressure points in your warehouse. Here are some key metrics to review if you’re looking to improve warehouse efficiency: 

• Picking accuracy – miss-picks can be a sign that something isn’t working or that capacity is being outstripped by demand.  
• Packing times – have packing times met targets? Are packers taking longer to process orders? During high-pressure times, packing times can be a bottleneck if processes aren’t efficient and packing materials aren’t easy  
• Dispatch lead times – do your dispatch lead times keep increasing and getting longer? This can be in response to high demand, but it can also suggest that processes need to change/  
• Damages – are customers reporting an increase in damages? This can be an indicator that packing isn’t being completed properly or that the packing materials being used aren’t sufficient.  

Ultimately, you want to try and avoid bottlenecks because they can all impact how cost-effectively you’re running your warehouse AND impact your customer. In fact, almost 40% of consumers report that the risk of goods not being delivered on time prevents them from shopping online!  

Common indicators of packing bottlenecks  

So, what are some common indicators packing bottlenecks? Here are some examples that you should watch out for:  

Untidy Pick Areas 

One common bottleneck in packing operations is untidy pick areas. Disorderly shelves and misplaced items can lead to inefficiencies.  As your team spend extra time searching for the right products and packaging materials their productivity decreases and their packing downtime increases – not ideal when you’re busy. This not only slows down the packing process but also increases the risk of errors. 

Slow Goods Out and Dispatch 

Another issue often encountered is the delay in goods going out for dispatch. This has a knock-on effect on your customers, as it could delay delivery timescales.  

Slow dispatch times can be caused by various factors, such as insufficient manpower, inefficient packing processes, or inadequate packaging materials. In addition, your warehouse layout could also play a part in this. Where your products and packaging are stored, as well as where key processes happen will affect overall warehouse movement.  

Running out of Packaging Supplies 

Have you ever run out of packaging during a crucial time? This can be a big bottleneck and bring your packing area to a halt, significantly hindering efficiency.  

This not only disrupts the workflow but also leads to delays in fulfilling orders. Not what you need when you’re busy. This can be caused by several things, including incorrect forecasting, inefficient stock takes, or not placing packaging orders in advance of busy times.  

Solutions to streamline your warehouse packing operation

If you’re experiencing any of these bottlenecks, don’t worry. There are lots of solutions you can put in place to improve productivity and streamline your packing operation.  

Regularly Reviewing Packing Processes 

Regularly reviewing your processes is crucial. You should be considering what works well and what doesn’t at least every quarter. If there have also been any significant changes – such as hiring lots of new staff – you may want to review processes then too. Fresh eyes can give you new perspectives or highlight where current processes might be challenging.  

In addition to the metrics we mentioned earlier in this article, you may also want to review KPIs like backorder rates, return rates, warehouse capacity and stock levels / continuity of supply of your packaging. 

Introducing Packaging Automation 

Embracing packaging automation in your packing process can significantly reduce bottlenecks.  

Packaging machinery can efficiently help you pick, pack, label and move orders throughout your warehouse. There are lots of different packaging automations available.  If you’re a smaller business, there are low scale options like desktop gummed paper tape machines, through to robotic picking, conveyors and case erectors for high-demand environments (and everything in between) 

Benefits of implementing automation include significant productivity improvements, as well as waste reduction and improved sustainability. Learn more here.  

Optimising Packaging Materials  

Not all packaging is made equal. Selecting the right packaging designs and material can make a substantial difference in how efficient your packing operation is. Having a concise, well-designed range of packing materials will enable you to pack and dispatch them quickly and effectively. It will also enable you to protect them more effectively and generate cost-savings throughout your operation.  

Consider the cardboard boxes you use. Are they easy to assemble? If not, that could be a bottleneck.  

If you’re wrapping pallets, do you know how much film you’re using to wrap a shipment? Is it more than you need?  

If optimising your packing materials is a concern for you, check out our Packaging Optimiser. It can show you the impact your materials and processes have on your business and the environment.  

Clever Packaging Swaps  

In some instances, your processes might be working well, so how can you squeeze some extra efficiency out of your packing operation?  

Implementing some clever packaging swaps could be key. For example, could you use longer rolls of void fill, packing tape or paper cushioning? This could reduce your downtime for roll changes and free up storage space. If you’re not using hoppers, you could introduce them and pre-fill them with key packaging materials, so your team will have what they need, when they need it, without leaving the packing area.  

Considering Redesigning Packing Areas 

The layout and organization of your packing area play a significant role in efficiency. Is your warehouse laid out as effectively as possible?  

If not, consider rearranging shelves, workstations, and storage areas to create a more streamlined and ergonomic workspace for your packing team. Even keeping packaging materials in the “power zone” (no higher than shoulder height) on pack benches and minimising twisting can lead to efficiencies.  

Support enhancing your packing productivity  

Streamlining your packing operation is crucial for meeting the demands of peak season and beyond! If you need support improving your packing productivity and streamlining your warehouse, Macfarlane Packaging is here to help.  

With a wide range of high-quality packaging materials, market-leading tools and e-trading systems, and expert advice, we are here to support your business in achieving seamless packing operations. Contact us today to learn more.  

The post Streamlining Your Warehouse Packing Operation: Resolving Bottlenecks  appeared first on Macfarlane Packaging.

We know this an important topic as we get towards peak. Last year, we found that 31% of retailers and 3PLs said productivity was their biggest problem during the high demand season of Q4.

As the demand for faster order fulfilment increases, businesses must constantly optimise their operations to remain competitive. Even a few small adjustments can have a big impact on how your warehouse operates…

In today’s article, we’ll discuss the benefits of boosting your warehouse productivity. We’ll also look at three simple equipment changes that can boost productivity, ultimately improving your overall business results.

Benefits of improving warehouse productivity

Improving warehouse productivity is important, as it directly impacts your overall operational efficiency, customer satisfaction, and bottom line.

Customer orders are processed and shipped faster, which leads to improved delivery times and better customer satisfaction and loyalty. So much so that, IMRG’s Home Delivery Review found that 40% of consumers say that delivery satisfaction impact’s their household decision when using a retailer.

A more productive warehouse can handle increased order volume without the need for significant expansions or additional resources. This leads to a benefital use of existing space and reduced overhead costs.

Other benefits of improving warehouse productivity include:

• Companies can save time and resources by improving processes and using them efficiently for equipment, staff, and inventory. This results in better resource allocation and increased efficiency.
• Enhanced productivity can help a warehouse handle larger volumes of inventory without needing to expand its physical footprint. This is particularly important in cases where expansion might be costly or impractical.
• A productive warehouse can handle increased orders during busy times, preventing delays and keeping work flowing smoothly.
• A well-organised and efficient warehouse provides a better work environment for employees. When staff members can accomplish tasks more easily and with less stress, job satisfaction tends to increase.
• Improved productivity can help a warehouse handle larger volumes of inventory without needing to expand its physical footprint. This is particularly important in cases where expansion might be costly or impractical. Especially this year, as it’s been reported that warehouse rental values across the market will rise by 5%. It should be noted that the Chartered Institute of Logistics and Transport UK has revealed that 86% of companies have experienced warehouse operative staff shortages in the past two years. So even if you can find the space, you might not be able to hire the staff to fill it.

In essence, improving warehouse productivity positively impacts various aspects of your operations. By investing in streamlined processes, technology, and employee training, businesses can enhance their effectiveness, customer satisfaction, and overall success.

Packaging solutions to increase productivity

Packaging solutions play a crucial role in increasing warehouse productivity by streamlining the packaging process, reducing errors, and optimising space. Below are three solutions that can help boost productivity in your warehouse:

1. Temporary Pick bins

Warehouse accessories, such as pick bins, are ideal for managing your packing areas and boosting productivity during peak periods.

Available in corrugated cardboard or Correx e.g. (corrugated plastic), temporary pick bins are made to order with a variety of customisable options to ensure your warehouse design works for you. You can choose the type of bin access you need, including fully and partially open faces, straight or chute fronts.

The design can include a tray inside the bin that helps to divide the bin, creating more places to pick items. Additionally, it allows for easy storage of related goods.

Pick bins that are mounted on the floor can come with extra legs so that they can be easily moved by pallet trucks and forklifts.  Extra shelves are also available to separate different products. This is especially helpful when you have similar items stored in different parts of the store.

By organising items in pick bins, pickers can quickly locate the products they need, which reduces the time spent searching for items and speeds up the overall picking process. Placing frequently picked items in pick bins near packing stations or shipping areas minimises the distance pickers need to travel. This reduces fatigue and allows you to process more orders in less time.

You can stack or organise corrugated pick bins on shelves, making efficient use of vertical space. Instead of picking from bins spread across the warehouse floor, pickers only have to touch the bins they’re collecting from. This minimises touch points and handling errors.

An added benefit of temporary pick bins is that they can be broken down and stored flat when not required too. This means they can be used to flex around production demand, such as the often quiet period after peak in January, where extra pick bins may not be required.

2. Automated Tape dispensers

Tape dispensers can boost productivity in warehouses by making it easier to apply tape to packages.

Using tape dispensers can speed up the process of dispensing tape, compared to doing it manually. This helps workers complete packaging tasks more quickly, leading to increased productivity within the same timeframe.

Manual tape application can be time-consuming and repetitive, leading to worker fatigue and potential downtime because of injuries or strains. Switching to automatic solutions reduces physical strain on workers and helps maintain a consistent pace throughout the workday.

Automatic tape dispensers provide consistent tape lengths, ensuring that every package receives the right amount of tape. This reduces the risk of wasting tape as well as helps lower overall packaging costs.

Overall, automatic tape dispensers help optimise packaging workflows by saving time, reducing waste, and increasing accuracy. When integrated into a larger packaging process, they contribute to a more efficient and productive warehouse environment.

3. Introducing packing guidelines at every packing station

It doesn’t matter if you have two team members or twenty; how they operate will make the difference!

Adding packing guidelines that cover topics from time management to best practices will not only help as we begin to prepare for the high-demand season, but help with daily life.

If you want to go the extra mile, why not think about providing extra staff training, too? That is why, you can ensure all packers know the best methods and tips to become more productive!

As we’re slowly making our way towards peak, now is a great time to start preparing. Can you think of any areas where you know you could improve?

How Macfarlane Packaging can help

At Macfarlane Packaging, we offer a comprehensive range of packaging materials, warehouse equipment, and packaging machinery, all designed to help you establish an optimal packing environment.

We know the pressures of rising costs when margins are being squeezed. It’s why we developed the Packaging Optimiser; a market-leading tool we can use to help you quickly and easily find the hidden costs in your packaging operation. It will also show you just how much you can save, with even quite modest changes to packaging, warehouse layout or processes.

We can assist you in achieving the perfect packaging solutions for your needs – whether you require sturdy boxes, protective materials, or efficient machinery, we have you covered. Don’t hesitate to contact us today and discover how our expertise can benefit your packaging operation. 

The post 3 quick warehouse equipment changes to boost productivity appeared first on Macfarlane Packaging.