The Packaging Challenge

An apparel distributor was on the verge of outgrowing its current facilities due to business growth and the current packaging processes taking up too much space.


The New-Tech Solution

Our team audited the packaging process, identifying problem areas and uncovering a solution that would speed packaging, replace an inefficient manual pack and ship process, and require minimal space.

Our recommendation included four custom-built automated packaging/bagging machines integrated with a new conveyor and package handling system for internet order fulfillment. 


The Customer Results 

In adopting this automation, the company saved on materials, labor, and freight.

  • Material costs decreased as a printed bag replaced a corrugated box, packing materials, tape, and labels.
  • The number of packages shipped per hour grew by over 50% with the same labor force.
  • The time to ship an order decreased from almost three minutes per order to 45 seconds! This allowed them to handle their growth without adding additional packaging stations.
  • Freight savings were substantial because the system was tied into a software program that identified the lowest cost to route the package.

Total annual cost savings were $200,000, with an anticipated higher return in the future as the equipment is fully amortized.