Your packaging isn’t just protection, it’s presentation. It’s the first thing your customer sees and the last step before your product’s promise is fulfilled. A dented box or damaged pack isn’t just a logistics issue, it’s a brand issue.

At Frontline Packaging, we know that damage-free delivery isn’t luck, it’s good engineering.

💡 Beyond Containment: Packaging as a Brand Experience

When a product arrives in perfect condition, it tells a story of consistency, care, and quality. But maintaining that standard from fill to pallet takes more than sturdy materials, it takes smart automation that keeps every element in sync.

Every misaligned conveyor, mistimed packer, or poorly configured palletiser creates risk. That’s why we design systems that work as one, protecting both your product and your reputation at every stage of the journey.

⚙️ Engineering Protection into Every Step

Product protection isn’t about adding more packaging, it’s about precision. We engineer for:

• Gentle product handling – Custom conveyors, guides, and pick systems that reduce impact and stress.

• Consistent pack formation – Automation that ensures every unit is perfectly positioned before wrapping or sealing.

• Stable loads, secure transit – Intelligent palletising and wrapping that protect your product through every mile of distribution.

Every design decision, from machine spacing to material selection, contributes to reducing risk.

🧭 From Fill to Pallet, Confidence by Design

Frontline’s approach is holistic, we don’t just sell machinery, we design systems that protect value. Whether it’s a high-speed line for retail packs or a secondary packing setup for bulk distribution, our automation ensures consistency, safety, and reliability throughout.

When your packaging line runs right, it doesn’t just protect the product, it protects the trust your brand has built.

📦 The Result? Reliability You Can See

Zero damage. Consistent quality. Fewer returns. And a stronger reputation that reaches your customers before your product even leaves the warehouse.

Because in packaging, perfection isn’t cosmetic, it’s commercial.

Protect your product. Protect your brand.
If your packaging automation needs to do both, drop us a message and let’s build a line that delivers integrity at every stage.

Automation is no longer a “nice-to-have”, it’s essential for companies looking to stay competitive, increase efficiency, and scale operations. But if you’re just starting your automation journey, it can feel like stepping into the unknown. Where do you even begin? Which machines? Which processes? How do you make sure the investment pays off?

At Frontline, we understand these challenges. Our mission is to provide clarity over complexity. We don’t believe in overwhelming you with technical jargon or one-size-fits-all solutions. Instead, we focus on straightforward, actionable advice, tailored to your unique site, your team, and your growth plans.

Start With Understanding, Not Hardware

Before recommending machines or lines, we take the time to understand your operations. Where are the bottlenecks? Which processes consume the most time? Which tasks could benefit most from automation? By answering these questions first, we ensure that any automation investment is strategically targeted, not just shiny machinery for the sake of it.

Tailored Solutions for Your Team

Automation isn’t just about machines; it’s about people. Our approach considers your operators, maintenance team, and supervisors, ensuring that the systems we design are intuitive, safe, and easy to maintain. By aligning technology with your team’s capabilities, we reduce downtime, simplify training, and maximise overall efficiency.

Planning for Growth

Automation is an investment in the future, and growth is rarely linear. That’s why our solutions are scalable and flexible, designed to evolve as your business does. Whether you’re expanding production, introducing new product lines, or optimising workflows, we make sure your automation adapts, not limits, you.

Turn Unknowns Into Answers

The unknowns of automation can feel daunting, but they don’t have to be. With the right guidance, those uncertainties become opportunities for improvement. At Frontline, we help you navigate each step, identifying risks, designing solutions, and implementing systems that deliver real, measurable results.

If uncertainty is holding your business back, let’s turn those unknowns into answers, action, and growth.

Contact us today to start your automation journey with clarity and confidence.

At Frontline Packaging, we’re often asked to “quote for a machine.” But what we actually deliver, when we do our job properly, is a solution. There’s a big difference.

We don’t just drop one into your production line and walk away.

Because in our world, success starts with one simple, often-overlooked question:
“What problem are you really trying to solve?”

Beyond the Obvious: What’s Actually Holding You Back?

When a customer comes to us asking for a wrapper, a collator, or a robotic arm, we take a step back. Why do you need it? What’s happening upstream? What’s happening after the pack is sealed? What’s the actual outcome you’re trying to achieve?

The issue might seem like a slow line, but maybe the real bottleneck is the manual changeover that’s eating up 30 minutes between SKUs.
Maybe it’s not just about speed, but about reducing operator fatigue on a repetitive task.
Maybe it’s about consistency, hygiene, space, or safety.

Identifying that core challenge means we can design automation that directly addresses it, no bloat, no guesswork.

🚫 Why “Buying a Machine” Can Be the Wrong Fix

Off-the-shelf systems might look convenient at first glance. But a catalogue machine that isn’t built around your workflow, your pack sizes, or your constraints can lead to frustration, retrofits, and ultimately underperformance.

It’s like putting a plaster on a pulled muscle, it might look like you’re solving something, but the problem still exists.

Here’s where our process flips the script:

✅ Discovery First. Then Design.

Every project we take on starts with understanding:

• What are your business goals?

• What happens on your line today, what works, and what doesn’t?

• Where are the pain points that waste time, money, or effort?

From there, we engineer a solution. Sometimes that means full-line automation. Sometimes it means a single, well-placed machine that unlocks a lot more value than expected.

What Does That Look Like in Practice?

Some real-world examples:

• A changeover bottleneck was solved not with a bigger machine, but with smarter controls and operator-friendly HMI, cutting downtime by 60%.

• A space-constrained site didn’t need to relocate, just a custom footprint layout and compact robotic cell to do more with less.

• A company struggling with product damage got a new case packing system designed for gentler handling, reducing returns and improving presentation.

These are wins you don’t get by just picking something from a catalogue.

🎯 The Right Solution = Better ROI

We believe in long-term value. That means:

• Fewer breakdowns because machines are working within their ideal limits

• Faster deployment because systems are designed to fit your space, not fight it

• Scalable automation that grows with your business, not something you’ll outgrow in 18 months

It’s not about being “custom” for the sake of it. It’s about solving the right problem, in the most effective way.

Thinking About Automation?

Then think about what you’re really trying to solve, and whether your current plans actually fix that.

If they don’t, or if you’re not sure, we’d love to help!

When most people think of packaging automation companies, they picture machinery catalogs, price sheets, and product pitches. But that’s not us.

At Frontline Packaging, machines are just the tools. The real value lies in solving the puzzle each customer brings us, where every business is different, every layout is unique, and every product has its own quirks. We don’t lead with a product. We lead with a conversation.

Every Business Is a Puzzle

Automation is never one-size-fits-all. Some clients come to us with a brand-new factory layout and a blank slate. Others are struggling with bottlenecks on a legacy line. Some are growing quickly and need to scale fast, while others just want to reduce manual labor and improve consistency.

That’s why our first step isn’t “Here’s a machine.” It’s “Tell us what’s happening.”

We gather data. We understand your throughput needs, packaging specs, operator environment, future plans, and financial parameters. Then—and only then—do we start solving the puzzle.

Not Just Solutions – The Right Solutions

We’re not tied to a single manufacturer or product line. That gives us the freedom to recommend the best-fit equipment for your exact situation—even if it’s not something we make ourselves.

This flexibility allows us to design:

• Hybrid systems that blend manual and automated steps

• Multi-format lines that handle a wide range of SKUs

• Space-saving layouts that fit tight factory footprints

• Custom tooling and conveyors built to your product

• Scalable systems you can expand in phases

We’ve even told potential clients not to automate, because sometimes, the smartest move is to wait. That’s the kind of honesty that builds long-term trust.

Less Selling, More Solving

Our process is consultative and collaborative. It includes:

1. Listening – We dig deep into your challenges, goals, and constraints.

2. Assessing – We evaluate what’s possible and what isn’t.

3. Recommending – We provide honest options, including pros, cons, and budgetary figures.

4. Owning the Process – If we move forward, we manage the project from start to finish.

And if we’re not the right partner for a specific challenge? We’ll say so. Because we’re not in the business of making a sale—we’re in the business of making things work.

The Outcome: Smart Automation That Actually Fits

When you stop selling machines and start solving puzzles, the results speak for themselves:

• Higher uptime

• Faster changeovers

• Smoother integration

• Fewer surprises

• A process that feels less like a transaction and more like a partnership

Ready to Solve Your Puzzle?

If you’re tired of off-the-shelf solutions that don’t quite fit—or salespeople who don’t take the time to understand your reality—Frontline Packaging is here to do things differently.

In a world of mass production and pre-packaged solutions, it’s tempting to assume that automation should work the same way, plug in a system, flip the switch, and expect results. But when it comes to packaging automation, the truth is clear: there is no such thing as one-size-fits-all. At Frontline Packaging, we’ve built our business around rejecting that idea.

Why “Off-the-Shelf” Doesn’t Work

Every production environment is unique, whether it’s the shape of your floor space, the complexity of your products, or your volume and speed requirements. Off-the-shelf automation solutions often come with compromises:

• You adjust your process to fit the machine, rather than the machine adapting to your process.

• You’re limited to what that system was designed to do, not what you need it to do.

• Future changes, like new SKUs or packaging formats, can mean costly retrofits or replacements.

That’s not just inefficient—it’s risky.

Built Around You, Not Around Constraints

At Frontline Packaging, we start by understanding your operation in detail: your goals, your challenges, your workflow. We assess everything from pack format and ergonomics to material flow and line layout. Then—and only then—do we start designing your automation system.

This isn’t automation for the sake of it—it’s automation with purpose.

Our custom-built systems are designed to:

• Integrate seamlessly with your current process and floor space

• Scale and adapt as your business grows or evolves

• Handle variability, whether that’s multiple formats, product types, or run sizes

• Minimize downtime with user-friendly controls and efficient changeovers

• Maximize ROI by ensuring performance, reliability, and long-term value

Flexibility Without Complexity

Custom doesn’t mean complicated. Our solutions are engineered to be operator-friendly, maintenance-ready, and upgradeable. You won’t find overbuilt machines or bloated systems—we build lean, smart, fit-for-purpose automation that’s as agile as your business needs to be.

Real Partnership, Not Just Supply

We’re not just machine builders—we’re project partners. From initial brief through to design, installation, and long-term support, we take responsibility for making sure everything runs as it should. And if we’re not the right fit for your challenge? We’ll tell you that too. No hard sell. Just honest advice.

If you’re tired of bending your process around someone else’s product, it’s time for a better approach, contact us today!

When most people hear “bespoke automation,” they picture something complex, expensive, and perhaps even unnecessary.

But the truth is, bespoke doesn’t mean overengineered—it means right-sized.

In the world of packaging automation, a tailored solution often delivers far more value than an off-the-shelf system. It’s not about bells and whistles—it’s about solving the right problem in the right way, for your product, process, and goals.

Why go bespoke?

At Frontline Packaging, we’ve seen firsthand how custom-built solutions can outperform standard setups in ways that really matter to manufacturers:

1. Precision fit for your process

No two production lines are the same. Bespoke automation takes into account your site layout, product fragility, pack format, throughput targets, and operator workflow.

Result?
A system that works with your operation, not against it. Less compromise, more control.

2. Designed around your product

From oddly shaped items to premium finishes that can’t be scuffed or dented, bespoke systems can be fine-tuned to handle your product with the right level of care and precision.

Result?
Lower product damage, better presentation, and reduced rework or waste.

3. Built for change

Bespoke doesn’t mean rigid. The best tailored systems are designed with future flexibility in mind—whether that’s tool-less changeovers, modular add-ons, or scalable layouts.

Result?
Your automation investment keeps paying off as your production evolves.

4. Support that understands your system

When a system is built specifically for you, support doesn’t feel like a guessing game. You’re not one of hundreds using the same machine—your setup is known, documented, and understood inside out.

Result?
Faster problem-solving, smoother maintenance, and minimal disruption.

5. Focused on value, not features

Bespoke automation doesn’t mean “everything plus the kitchen sink.” It means focusing on the features and functions that actually bring value to your operation—no more, no less.

Result?
A leaner, smarter investment with real ROI.

So, what’s the real value?

Bespoke automation isn’t about doing more—it’s about doing what matters. It’s automation that’s made to fit you, not the other way around.

At Frontline Packaging, we take the time to understand your operation, and we only recommend a tailored solution when it truly adds value. Sometimes that means building something from scratch. Sometimes, it means tweaking what you already have.

Either way, the goal is the same: an efficient, flexible, and future-ready packaging process that works for you.

Thinking about upgrading your packaging automation?
We’d love to hear about your goals and help you find the solution that fits.

Reducing carbon emissions is a critical goal for businesses aiming to enhance sustainability and meet environmental regulations. One effective area to focus on is packaging, where strategic changes can lead to significant emission reductions.​

1. Optimise Protective Packaging

Damaged products not only affect customer satisfaction but also contribute to increased carbon emissions due to the need for replacements and additional shipping. Each damaged item can add approximately 18.3 kg of CO₂ emissions into the atmosphere. Implementing high-quality protective packaging solutions—such as paper, air, and foam inserts that cushion impact and minimise product movement—can significantly reduce damage rates. Utilising automated, on-demand inflatable air systems allows packers to use the precise amount of material needed, reducing waste and lowering environmental impact.

2. Select Environmentally Friendly Materials

The choice of packaging materials plays a vital role in emission reduction. Opting for recyclable materials and those made from recycled content helps decrease the demand for virgin resources and minimises waste. For instance, air cushions made with 50% post-consumer recycled content require less petroleum in their production, thereby reducing associated emissions.

3. Implement Sustainable Design Practices

Designing packaging with sustainability in mind involves reducing material usage, optimising size and weight, and ensuring recyclability. These practices not only lower emissions during production and transportation but also align with consumer preferences for eco-friendly products, potentially enhancing brand loyalty. ​

4. Enhance Supply Chain Efficiency

Efficient packaging contributes to better palletisation and fuller truckloads, reducing the number of trips required for transportation. This improvement in logistics directly correlates with lower fuel consumption and reduced greenhouse gas emissions.

5. Engage in Industry Collaborations

Participating in initiatives and partnerships focused on sustainability can amplify efforts to reduce emissions.Collaborations with organisations like the Waste & Resources Action Programme (WRAP) provide access to resources and best practices for implementing circular economy principles in packaging.

By focusing on these strategies, brands and businesses can make substantial progress in lowering emissions through thoughtful packaging choices, contributing to environmental preservation and meeting the growing demand for sustainable practices.​

Following the announcement of the UK’s 2024 Autumn budget, UK businesses are set to face significant increases in costs associated with labour throughout 2025. The jump in employer National Insurance contributions will be a headache for many and mean that companies will need to look at where they can tighten their belts.  

Compounding this, the UK labour market has cooled substantially from post-pandemic highs and remains challenging, compared to the last two decades. It’s getting harder to recruit and retain staff, particularly in logistics and operations-based roles. Last year, it was reported that some 76% of logistics leaders were experiencing notable workforce shortages.

So, how can business maintain efficiency whilst mitigating increased cost impacts? Packaging automation could be key. Have you ever considered it?

In this article, we will give a brief overview of packaging automation, explain how it can help you tackle increase in labour costs from rises in National Insurance contributions and provide examples of packaging machinery you can consider.

What is packaging automation?  

Packaging automation is the process of packaging products without or with less manual human intervention, using machinery to assemble or dispense packaging materials.

It can also involve the movement of product or parcels throughout a warehouse between picking, packing and dispatch sites.

5 signs your business needs automated packing processes  

So, how do you know if packaging automation is right for your business? Here are five signs you can consider:

1. Your packaging is increasingly taking up room in your warehouse

1. You continually need to hire new staff for your production and/or packing line

1. Your packs produced per hour isn’t increasing in line with demand

1. Your business is creating increasing levels of packaging waste

1. You experience an uplift in customer complaints about damaged goods (if demand is too high, packing quality could be less reliable)

If you’ve said, “Yes” to just one of these signs, it might be worth you considering if you can automate any part of your packaging processes.

How packaging automation can reduce costs associated with labour and NI contributions 

Labour costs, including employer National Insurance contribution, represent a substantial portion of many companies operating expenses. The good news is that implementing automated packaging systems can drastically improve your productivity, lower costs in multiple areas and enhance your sustainability without the associated increase in headcount.

Let’s look at the benefits packaging automation offers:

Labour costs, including employer National Insurance contribution, represent a substantial portion of many companies operating expenses. The good news is that implementing automated packaging systems can drastically improve your productivity, lower costs in multiple areas and enhance your sustainability without the associated increase in headcount.

Let’s look at the benefits packaging automation offers:

• Reduced pack times & increased throughput – using packaging machinery can significantly speed up your packing operation. In practice, automated packing systems can double your throughput without the need of increasing your headcount.

• Fewer manual touch points – implementing packaging automation means you have a reduced requirement for human intervention. You could reallocate resource or use less packers, while productivity increases.

• Lower labour costs long-term – the combination of increased productivity but the need for less manual intervention means you can look to lower labour costs long term and may need a reduced headcount. Plus, automation can reduce (or even eliminate) the need for seasonal labour hires during peak periods. Savings can range from 25% to 50% once a piece of machinery has returned on investment.

• Enhanced health and safety – automated packaging solutions eliminate the need for your team to perform physically demanding or repetitive tasks, reducing the risk of workplace injuries and associated costs.

• Reduced waste & packaging use – employing packaging automation means you can cut the amount of packaging use, and the lack of human error means the right amount of packaging is used every time. This helps you reduce waste and can enable you to lower the cost of your packaging consumables while improving sustainability.

• Improved packaging cubage – packaging that is formed by machinery can ensure a consistent parcel cubage.

• Lower transport emissions and costs – consistent parcel cubage combined with eliminating excess packaging material use, ensures that your packages can be lighter. In turn, this will reduce the emissions associated with moving your parcels and help you tightly control courier or fuel costs.

• Fewer damages & returns – the consistent packaging provided by automated packing systems ensures your packaging quality is maintained. This will help reduce damages and associated returns – along with the reverse logistics costs. Another great saving!

Ultimately, while labour costs and NI contributions rise, investing in packaging automation can help you mitigate or offset increased financial burdens associated with these areas. The wide-ranging benefits of using packaging machinery can also deliver savings in other areas of your supply chain, while future-proofing your packing process against spikes in demand and seasonal peaks.

Popular examples of packaging machinery  

While almost any part of the packaging process can be automated, there are some key types of packaging automation systems that are used to enhance productivity. Some popular examples include:

• Case Erectors: these machines automatically construct boxes, saving time and ensuring consistent quality. They are usually fed with cases which are “popped” open and the bottom flaps of the box are sealed.

• Pallet Wrappers: machines for securely wrap pallets with minimal material waste, improving load stability during transit. The most popular types of pallet wrappers are usually turntable stretch machines, which rotate a pallet while it is wrapped.

• Case Sealers: often used in tandem with case erectors or right size box machines, this type of automated packaging system seal boxes quickly and uniformly, enhancing productivity and reducing material costs. These machines can use tape or glue to effectively seal boxes shut.

• Automatic Tape Dispensers: a small but powerful solution, automatic tape dispensers offer a quick way to enhance box sealing. They’re smaller than case sealers but still offer productivity and cost reduction advantages.

• Void Fill and Cushioning Systems: whether you want to use paper void fill or air cushions, there are many on-demand solutions that can be use as stand along machines or integrated into a production line, producing protective packaging as and when you need it.

• Strapping Machines: from battery-operated friction welders through to full automated strapping machines, this type of packaging equipment will seal, tension and cut strapping or pallet banding efficiently to stabilise packages for transportation.

Why choose Frontline Packaging for packaging automation? 

Frontline Packaging is a trusted partner in delivering customised packaging automation solutions – including consultation, supply of machinery and packaging consumables.

If you choose to work with us, you can expect:

• Custom packaging automation solutions

• Expert support and packaging design

• Leading machinery brands

• Illustration of financial, operations and sustainability savings

Conclusion 

In an era of rising labour costs and employer contributions, packaging automation offers a practical solution for businesses looking to improve efficiency, reduce operational expenses, and remain competitive. From case erectors to pallet wrappers, automated systems streamline processes, minimise manual effort and deliver consistent results.

If you’re ready to explore how packaging automation can benefit your business, contact Frontline Packaging today to discuss your requirements and discover the best solutions for your needs.

Its estimated that 87% of households made online purchases. This means that there are more parcels being delivered in the UK than ever before, making packaging a critical commodity for businesses who retail online. But what if that packaging is failing?

Damages are a huge cost to retailers and consumers alike. In fact, the IMRG estimate 0.3% of all parcels are lost or damaged in transit – which is over 9.4m packs each year.  Financial losses caused by damaged product cost the industry millions each year, and it’s not just the physical cost you need to consider…

Internet and omni-channel retailers are at the mercy of their customers and their ever-growing expectations. A poor delivery experience can result in loss of goodwill and repeat sales, especially when you consider that a parcel (and the packaging) is a consumer’s first physical interaction with a brand.

Then there’s the environmental cost. Every time a product is damaged the carbon cost of a transaction at least doubles and possibly even triples when you factor in the additional packaging and transport required to deal with reverse and replacement goods.

So how can you tackle damages?

Understand damage touch points

To get a real picture of the impact damages could be having on your business, you first need to consider all your damage touchpoints. These include:

• The value of the item(s) damaged
• Associated fines (e.g. courier or marketplace fines)
• Labour & processing costs / time expenditure
• Transport costs & emissions

Taking stock of these factors can give you an idea of what damages are truly costing your company.

Common packaging pitfalls that can lead to damages

After understanding the cost of your damages and returns, reviewing your packaging is your next stop. There are common packaging pitfalls that can lead to product getting damaged in transit. Keep an eye out for:

• Not enough or inappropriate protective material being used – fluctuations in packing or inconsistent packing materials can mean items are more prone to damage. Less protection can often equal more damage but there’s a fine line – you don’t want to use excess packaging either, which can be wasteful
• Too much space in a box – if you’re packing product and leaving space unfilled space in a box, your products can move around during transit. In-box movement means that your goods can more easily be damaged as they could hit pressure points or be prone to being crushed
• Inconsistent packing processes – if your team of packers all pack products differently or use different materials there are going to be different levels of protection across all the packs you dispatch. Putting packing guidelines in place that maintain consistency will help you control damages more effectively (as well as lower waste and improve pack appearance)
• Compromised packaging quality – where and how you store your packaging could impact the way it performs, and in turn impact damages. Don’t risk using any packaging that’s got wet or kept in very humid environments. Making sure your packaging is kept in a clean and dry environment will help make sure if performs like its meant to and protect your products

The impact of the right packaging

Ultimately, packaging that’s optimised can have a significant impact on successful delivery of goods. When packaging is designed and used properly it can help you protect your products and your brand, as well as reduce your costs.

The right packaging solution will also help you lower emissions associated with product damage and help you leverage customer loyalty too, as you’ll be creating an experience that meets or exceeds expectations.

For help perfecting your packaging, email info@frontlinepackaging.com and request an appointment with one of our experts.

It can be really difficult to decide what packaging solution is best for your business, especially when there’s so many options available. You might have heard about packaging automation and how it can transform your process. But what are the pros and what are the cons?

First of all, what kinds of packaging solutions are available today?

No automation

Without packaging automation, hand wrapping or using some other packaging medium is required such as shrink hood or strapping. The process takes much longer, but only in terms of direct labour involvement. There’s inconsistency in terms of packaging applied, depending on how tired the operator is and how rushed they might be with the workload. Having no packaging automation is overall a slower process, more labour intensive and therefore pretty costly. Not only that, but the results of the packages will ultimately vary due to different operator focus and fatigue.

Semi automation

An example of this is using a stretch wrapper, where the wrapping cycle is instigated, loaded and unloaded by someone. It doesn’t take long for the operator to load and start the process, it can be done in just a few seconds. The system then does the rest and usually provides consistent results. However, the initial cost can be a challenge, and the reliance on equipment might mean less staff, and so in the case of emergencies there is a degree of exposure to risk if the system should stop working. There are many lasting-pros to semi-automation, nonetheless. These include consistent finish to the packaging, a higher speed of process, and freeing up labour constraints. But it still allows operator’s to “play” with the packaging if they need to.

Full automation

This sometimes includes a palletiser feeding a wrapper by means of conveyors. Sometimes automatics are stand-alone systems, and although they are loaded and unloaded by an operator, things like the infeed and collation wrapping is all done automatically by the system. This usually removes the need for an operator completely, however like semi-automation, this can be an issue if the fully automated system stops working suddenly and contingencies aren’t available or in place. Another challenge is cost, as this kind of equipment can be expensive in the outset. But it does result in a very high throughput and consistent results which simply cannot be matched by labour, and in turn will save money in the long run.

Why might I consider installing an automated packaging system or machine?

Security

With some carefully selected automation, you can speed up the way you secure your packages for delivery, and make sure they’re not going to be returned. Automated stretch-wrapping, for example, can increase the speed palletised loads can be tightly secured, while also reducing the need for manual intervention and maximising the yield from each roll of film.

Space saving

By creating more space in your warehouse, you can improve pick/pack timings and on-site efficiency. Some traditional void fill systems such as polystyrene chips or conventional bubble wrap are pretty bulky to store and hard to handle. Automated void fill systems such as paper or air based solutions are a great way to reclaim that valuable space.

Waste reduction

By using an automated system or machine, you can make sure your packages are consistent in aesthetic, so you don’t need to replace items and waste incorrect packaging.

Consistency

Automated and semi-automated strapping makes it possible to increase the speed with which packages and boxes can be secured for shipping. And because they’re mobile, they can be easily moved to packing stations experiencing high throughput. This not only speeds up the load strapping, but also improves the consistency of your packages.

Labour constraints

There are a number of automated packaging solutions designed to speed up the packaging process, freeing up workers to perform other tasks, and in turn reducing costs. This can be anything from an automated stretch wrapping machine, to box erectors and sealing machines. Where hand stretch wrapping a pallet might require two people, after introducing an automated stretch wrapper, the process will only require one.

Speed

You could use automated stretch-wrapping to increase the speed palletised loads can be tightly secured, while also reducing the need for manual intervention and maximising the yield from each roll of film. Automated and semi-automated case erectors have a compact footprint, but can drastically speed up the erection and sealing of a wide variety of cartons, boxes and cases. User-friendly automated tape application machines seal both the top and bottom of your boxes automatically. Being easy to adjust for different case sizes and mobile enough to use flexibly, they really speed up sealing on different packing stations, on demand. This frees up packing operatives, and not only makes the assembly faster, but also much safer.

Volume

Automated systems are more likely to help you cope with increasing volumes of packaging. So as your business grows, your packaging system keeps up to speed.

Safety

Back injuries from manual handling are a major cause of occupational ill health. Over a third of injuries lasting three-days or more reported annually to the HSE are caused by manual handling. Switching from stacking pallets by hand to automated solutions is far less risk averse. It can also significantly increase your production output and save costs on transport and labour.

If I already have an automated packaging machine or system, why should I consider adding to what I currently have, and what options are available?

If your existing equipment isn’t good at dealing with the growth in output, or the age of your equipment means it’s not as up-to-date in efficiency, you might want to update your system a little.

Having an outdated system might mean the technology is redundant, and new equipment would reduce the maintenance costs and give the end result of improved aesthetics and security. This will result in happier customers and help you to avoid any additional replacement costs.

What’s more, you could need a redesign of your factory in terms of flow and access. Or you might need changes to product specification such as height, weight, and stacking patterns stability.

What are the key considerations when buying an automated packaging machine or system?

First and foremost, it’s important to understand what you need now, as well as what you might require in five years’ time. Look at the quality in terms of system build and reliability. You’ll also need to look at the system’s performance by trialling and making comparisons with other brands.

Ask yourself: how well is the system warrantied? What’s the cost of ownership in terms of servicing, parts, breakdown and depreciation? Is it suitable enough for your products and workflow? Does it cover the range of sizes and weights for your products? Is it stable enough?

And of course, always look into the brand reputation and customer loyalty, too.

How should I budget for my new system?

Prepare a justification/payback based on current costs and criteria such as load security, labour savings, consumable cost reduction, packaging waste reduction, and savings due to increased throughput and output.

Look at cost of ownership versus current cost, and future costs if no change is made. Also look at the longevity of the equipment (basically, don’t buy for cheap and cheerful!)