A guide to entry, mid and top-level packaging automation solutions
When you hear the term “packaging automation” or “packaging machinery” it can be easy to think that the term relates to large-scale systems that involve an expensive outlay. But that doesn’t have to be the case.
Packaging automation can have significant benefits, including helping you combat incoming costs associated with National Living Wage and employer National Insurance contribution increases.
So, is there an automated packaging system for you? Whether you have a simple goal like making taping a parcel easier or speeding up how you wrap a pallet through to aiming for complex strategic improvements to your warehouse movement, there’s a packaging automation solution for you!
In this article, we’ll dive into an overview of packaging automation and what it offers, as well as highlighting types of automated packaging systems that offer entry-level, mid-level and top-level solutions.
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Defining packaging automation
Packaging automation is the process of partially or fully automating how you pack your products for shipping. In essence, it involves using packaging machinery and equipment to automate some of your packing process, removing manual touch points.
You can choose to automate just one part of the packaging process or automate your full process, including picking, packing and movement.
Key benefits of implementing packaging automation
There’s a whole host of benefits you can enjoy when you implement packaging automation. Some of the key benefits of using an automated packing system include:
- Drastically improving your productivity
- Lowering your packaging waste
- Cutting labour and operational costs
- Optimising your storage space
- Maximising your transport so you can deliver more in fewer vehicles
- Lowering carbon emissions in your supply chain
- Enhancing quality control and minimising packing errors
- Futureproofing your packing operation
For example, if you implemented a right size carton system, which makes boxes exactly the right size for your products, you would significantly reduce waste and improve parcel cubage. This, in turn, would help you reduce the transport you need to deliver your parcels, resulting in lower costs and reduced CO2 emissions.
So, how do you know if your operation is ready for a packaging automation system?
Understanding when it might be time to automate your packaging processes
There can be clear signs that you operation might benefit from automating packing processes. Some of the key things our experts recommend you look out for include struggling to keep up with demand and increasing instances of damages
Why not watch this video that explains more?
A guide to entry, mid and top-level packaging automation solutions
Now, if you’re ready to take the dive into packaging automation, where should you start? Here’s a whistlestop tour of automated packing solutions from entry-level through to high-demand machinery.
Entry-level packaging automation solutions
Packing machinery doesn’t have to break the bank. Small solutions can offer a big impact. Some examples of entry-level automation include:
Gummed Paper Tape Machines – these compact but efficient electronic tape dispensers will moisten and dispense lengths of gummed paper tape at the touch of a button. Available in a range of models, they can be bought for less than £1,000 and can help improve packs and cut the amount of tape you need to use.
Friction Welders – if you’re strapping pallets by hand using polypropylene or polyester strapping, a friction welder could make your life easier. These battery-operated handheld devices will tension, cut and seal strapping for you at the touch of a button.
Semi-automatic turntable stretch wrappers – pallet wrappers can seem like big pieces of equipment, but if you’re wrapping 15 or more pallets a day, installing a semi-automatic turntable pallet wrapper, like the Robopac Ecoplat, can help you wrap more pallets with less film. Not sure what stretch machine you need? Book a stretch wrap review for a tailored recommendations.
Individual void fill machines – whether you have a preference for paper void fill or air bags, individual void fill machines on a packing bench can be used to create protective packing material on-demand, saving time. Many models, like the Pregis Mini Pak’R or the RanPak TT machine offer plug-and-play operation and have a small footprint, so your warehouse space isn’t compromised.
Mid-Level Packaging Automation Solutions
If you’re already using some smaller automated systems listed above and you need another productivity boost, you could also consider these mid-level packaging automation solutions:
Case erectors – perfect if you’re using a significant number of boxes, case erectors will take a pre-formed case or box, and pop it open and seal the bottom flaps, ready for packing. This speeds up the packing process and helps with uniform parcel cubage, which will help reduce damages, improve pallet stacking and can even contribute to lower transport costs. Operations from just 2-3 packers can benefit from this type of automation.
Case sealers – standalone case sealers will seal boxes using tape or glue. They can be used alone or alongside case erectors. Models are available for mid-range all the way up to high-demand solutions. They can help you accurately control tape usage and cut waste.
Integrated void fill systems – if you’re operating a multi-bench packing area, having void fill on demand at each bench can be important to ensure your products are protected. Many systems can be mounted to fill hoppers or multiple workstations, replenishing air bags or paper cushioning automatically.
Vertical auto bagging machines – this type of bagging machine allows you to insert product and then seal and often label or print it all in one go. There are systems available that can enable you to produce 50 packs per minute. Applications including ecommerce and mail order fulfilment, hardware, automotive and appliance parts, plumbing and heating parts, medical devices and many more.
Strapping machines – if you’re bundling product, securing boxes or even strapping pallets, strapping machines can help you apply, tension, cut and seal strapping with ease.
Top Level Packaging Automation Solutions
For even the most demanding operations, there are a huge range of packaging automation solutions available. Key types of top-level automation systems include:
Right size carton systems and void reduction systems – combining dazzling speed with the ability to create the right size box for your products, these machines ensure you’re using the ideal size packaging every time. They enable you to maximise cubage and reduce the void in a carton, so you’re not paying to ship empty space. Right size carton systems work by taking blank cardboard and forming it around your products. They can be combined with void fill dispensing and will also seal a lid onto your carton.
Automatic random case sealers – the high-end of the case sealer machine market, random case sealers will seal a range of boxes, rather than just one standard size.
Horizontal auto bagging – enabling you to bag products in-line, horizontal bagging machines will create bags by sealing film while product or boxes flow through them, sealing them inside. They can print and label bags too, ready for shipping.
Conveyors, movement & labelling – in addition to key packing processes like boxing, sealing, stretch wrapping and bagging, all movement in your operation can be automated with conveyors. Auxiliary actions like labelling or document insertion can also be automated, minimising manual touch points, so your operation runs fluidly from start to finish.
Automaton savings in practice
So, how does implementing packaging automation really compare to a manual process?
The below real-life example (calculated by our Packaging Optimiser) shows the labour cost-saving impact of switching from a manual bagging process to automated bagging. The business was packing 650,000 parcels a year.
| Manual Process | Automated Process | |
| Time to pack 1 parcel | 40 seconds | 5 seconds |
| Time packing per day | 2:53 hours per day | 22 minutes per day |
| Number of packs per day | 260 / 90 per hour | Up to 720 per hour |
| Packing cost per year (inc. labour & materials) | £104,000 | £44,258 |
| Annual Saving | Speed Improvement |
| £59,742 | 8x faster |
This is an astounding saving, so it’s worth noting that this example does not show all the other benefits throughout this businesses supply chain, such as damage reduction and reduced carbon emissions.
Support with packaging automation
At Macfarlane Packaging, we have dedicated experts who can help you start your packaging automation journey. From consulting on the right solutions, supplying the packaging machinery and materials through to demonstrating return on investment – we’re here to help you overhaul your packaging operation.
Get in touch to book an appointment with Macfarlane’s automation experts today.