Large Fulfillment Center

We helped a large fulfillment center automate their line to double output while lowering costs.

The Problem

Time-consuming and labor-intensive

A large fulfillment center was using a time-consuming and labor-intensive, 10 employee, process-to-fill, label, and seal bubble mailers at a rate of 1,000 to 1,200 pieces per hour. We were tasked with reducing total cost while increasing the output of the overall operation.

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The Solution

New automated system

We installed two Pac Jacket machines which were able to make the poly bubble bags in line and seal the package at the same time. We then installed an automatic printer to apply the correct printed barcode onto each package. The new automated system only required a worker to drop the product into the pouch as it advanced down the line.

The Impact

Overall output doubled

The client was able to reduce the total number of employees needed to work this line from 10 to 2 per machine. The overall output doubled to 2,000-2,400 pieces per hour, while the price per unit was lowered by $0.02.

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