Automating Box Size Changeovers Optimizes Case Packing for E-Commerce Fulfillment

E-Commerce fulfillment necessitates the use of flexible end-of-line automation to sustain high throughput, reduce freight costs and minimize the use of packaging materials. Critical to streamlined e-commerce fulfillment is automated form, pack and seal case packing.

BEL 5150E form, pack and seal machine for eCommerce fulfillment.

The most advanced automated case packing systems – such as the BEL 5150E form, pack and seal machine from Wexxar Bel – provides a highly flexible and completely integrated case packing e-commerce fulfillment solution, with the ability to perform quick and automated box size changes.

E-Commerce creates significant challenges for online retailers, who often struggle to meet the demands of buyers. Growing at an average of 15 percent annually, e-commerce is inherently unpredictable. Managing high volumes of SKUs, smaller numbers of pieces per order, changes in
market demand due to seasonality and popularity, and increased expectation for same-day and next-day delivery demands highly specific fulfillment applications.

The sometimes erratic and chaotic pace places stress on companies to expand their production capabilities quickly in a way that generates a shot-term return on investment (ROI).

Pick, pack, and ship operations must be able to track changes in the market and react immediately to them. This requires an automated capability that is both flexible and scalable. Automating such capabilities has typically been a luxury reserved for larger online companies. For small to medium-sized e-tailers, the changes accompanying rapid growth can be particularly daunting.

Many small online retailers hand pick and hand pack their orders. Paper-based operations are not uncommon. Inventory is often stored on the floor or on racks, with case picks and pallet picks used to fulfill orders. These systems are easily taxed by larger quantities of online sales, particularly those with multiple-SKU orders. Such e-commerce companies need a solution for efficient throughput that can scale upwards as they grow.

Forward-thinking e-commerce companies must predict what their demand will be several years down the road. If projections favor increased sales, they may invest in systems that automate their end-of-line fulfillment processes. These systems must be capable of managing high volumes of throughput with real-time visibility, while maintaining precise accuracy.

An increasingly frequent request from end-of-line packagers of e-commerce products is their need to reduce operator interaction with their case forming systems. The more complex the interaction for the operator, the higher the chance of human error in the process. Automation that allows operators to start and run a case forming, packing and sealing machine without needing to make adjustments will increase order fulfillment accuracy, uptime and throughput.

A good example of automated case packing for e-commerce fulfillment is the BEL 5150E form, pack and seal machine from Wexxar Bel. For almost 50 years the company has been a leading manufacturer of automated case erectors and sealers for consumer product packaging applications. This latest generation of machines is focused squarely on increasing e-commerce flexibility and speed by automating what previously required operator interaction.

Box Packing Automation
Designed for E-Commerce Fulfillment
The machine's automated case form, pack and seal system incorporates unique technology into one fully-integrated, flexible and high-speed system to support e-commerce fulfillment.

Auto-Adjust Case Size Changeovers
The BEL 5150E is the first semi-automatic case forming, packing and sealing solution with auto-adjust case size changeovers, designed primarily for low to mid-speed e-commerce applications.

E-Commerce fulfillment typically uses between 8 and 15 different box sizes with multiple different sized products. This system has the capacity of up to 30 different box sizes, with the ability to expand if necessary.

Operators manually select a box size either from the HMI screen, or an integrated input tool like a barcode scanner. The machine then selects the proper box sizes and automatically makes the necessary adjustments for each product. The machine holds the formed case in place as the operator ergonomically packs the case with both hands free.

When equipped with a pick-to-light case rack, the BEL 5150E directs the operator to pick the correct case blank ensuring the right case is always used. Having the optimal case size picked and used offers tremendous savings in shipping costs, dunnage costs and reduced chance of product damage.

Integration with ERP
Tracking the entire process from order picking to shipping, this system achieves the best results when integrated with a WMS and ERP system. As picked orders approach the packing station, the ERP system sends a signal to both the case packer and the operator to advise on the most optimal case for that order. The case former/packing station will then begin changing sizes to accommodate the selected case, while the operator loads the proper sized box.

Once completed, the order is verified and the box sealed, and moved on to be labeled and shipped. The case packer then receives the next case size information to begin a new pack cycle.

Accurate Dimensioning of Boxes
Companies providing e-commerce fulfillment are more incentivized than ever to pack their products in the smallest sized packaging possible. The use of one-size-fits-all packaging for a range of product sizes, while it may increase throughput, effectively translates to paying extra money to ship air.

This latest model of automated case packing streamlines the entire end-of-line e-commerce fulfillment workflow, which translates to substantial ROI for e-commerce companies, large and small.

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