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Category: Weighing & Measuring

Journey of Sustainable Packaging

Posted on by David Priestman

With the packaging industry eagerly anticipating the first interpack in six years, Hugo Beck – a world leading specialist in horizontal film packaging machines, flowpack and paper packaging machines as well as automation solutions – is welcoming visitors to its stand to see at first hand the significant improvements in machinery for sustainable packaging, including a brand-new solution for paper packaging.

Since the last interpack in 2017, Hugo Beck has invested heavily in introducing new film and paper packaging machines, as well as in improvements to existing machines and capabilities.
These advances will be showcased on the Hugo Beck stand, which will take visitors on a journey through the options available in paper and film packaging. Hugo Beck promises ‘the highest flexibility for today’s markets and tomorrows.’

A key focus will be on the ability to deliver sustainable packaging concepts and resource-saving machine technology. This includes futureproofing customers’ packaging processes through the integration of flexible, fully automated packaging machines, which help to reduce material consumption, drive greater efficiency and improve recyclability.

On the Hugo Beck stand (Hall 11, Stand G39)

– The Hugo Beck stand is highlighting individual packaging solutions for diverse industries and products. A brand new flexo paper packaging solution will be introduced to the market as a cost-effective entry model and a space-saving machine solution. As a hybrid variant of the company’s flexo machine series for paper and film the machine can be changed between packaging materials within minutes, making it perfect for a number of industries from e-commerce and logistics through to many others.

– The paper e-com fit for paper packaging, which is ideal for e-commerce applications, automatically adapts the size of shipping bags to the varying length and width of products. Different product sizes up to 200 mm tall can be packaged in a jumble using a minimum amount of paper. The precisely fitting paper bags feature two sewn sides plus a glued top overlap. As such, it opens up new possibilities for sustainable shipping packaging for the e-commerce, mail order and logistics sectors when it comes to direct dispatch of individual goods, packing groups of products or meeting the complex requirements of returns packaging.

– The flowpack X is a modular solution for air-tight film packaging and paper packaging. Easily adjusted to process varying packaging materials with a short changeover, and capable of coping with the most diverse heat and cold-sealable paper-based packaging materials and films with different thickness, the flowpack X enables optimum functionality for manufacturers seeking sustainable packaging materials. Offering air-tight film packaging, it is perfect for pharmaceutical or medical technology, but the flowpack X provides customers across multiple industries with ultimate flexibility and security when working with a variety of packaging materials.

– The continuous servo X Form Fill and Seal machines are capable of material savings of 60-70% through minimal use of film targeting diverse industries. Minimising the use of packaging material in the first place is a key requirement for sustainability. The servo X machine series is designed to ensure film use is as efficient as possible while delivering a consistently high, or even increased, output across all types of machine-compatible films, such as mono-material films, recycled content films and bioplastics. The amount of film required is reduced by simply using the company’s extremely tight packaging technology, which delivers a precision fit of the film and hardly any film waste during production. The environmental profile of film packaging can also be optimised by making it as thin and light as possible. Packaging machines from Hugo Beck process extremely thin packaging and shrink films starting from only 7 µm.

SEW-EURODRIVE is exhibiting Hugo Beck’s latest flowpack X for paper packaging, which is available with complete machine automation solutions from SEW-EURODRIVE on request. The selected drive and automation components from SEW-EURODRIVE have been expanded specifically due to Hugo Beck‘s sustainability requirements and now include components such as energy storage units and stepper drives. The use of an intelligent energy management system and the replacement of pneumatic drives with electromechanical drives significantly and measurably reduces energy requirements and makes compressed air unnecessary.

The use of an energy storage unit, in conjunction with the software modules from SEW-EURODRIVE, leads to stabilisation of the power supply and bridging of short-term voltage dips, to reduced peak loads as well as to controlled stops in the event of longer power failures. This means that the machine can also be used when the power grid is not stable or even when a power failure is expected.

“We’re looking forward to welcoming visitors to interpack, to see the huge strides we’ve made in terms of product development since the last show,” commented Timo Kollmann, Managing Director of Hugo Beck. The world has changed a lot over the past six years, with an increased focus on sustainability and significant growth in sectors such as e-commerce. Our latest solutions help customers to meet their challenges in terms of increased sustainability while still delivering on the key requirements for effective packaging such as protection and preservation of products.”

 

Weigh in Motion technology at LogiMAT

Posted on by David Priestman

Imagine a logistical world in which you can weigh your palletized goods on the go. No stops involved. Always accurate and real-time data on weight and possibly dimensions. Visit the RAVAS booth C75 in hall 10 at LogiMAT and witness this technological revolution yourself.

Intelligent carriage plate with Weigh in Motion technology

Last year, RAVAS introduced the iCP, an intelligent weighing carriage plate that enables you to weigh ‘difficult to pack’ products in combination with pre-construction equipment, such as a clamp or rotator. The iCP is available in a wired and wireless edition, and more importantly, as an OIML version. This Legal for Trade validation allows you to invoice your customers by weight.

But technological innovation never stops at RAVAS. Where drivers in the past had to physically stop the forklift truck for a few seconds to generate the weight, our engineers now have developed Weigh in Motion technology that enables you to weigh on the go, without stops nor interruptions. Driving at a constant speed on a smooth floor, generates a real-time and reliable set of data on weight and volume that can be transferred to any ERP or WMS and can be used to invoice your customers by weight. This Weigh in Motion technology is an absolute revolution in the optimization of every supply chain.

Display on the handle

Furthermore, RAVAS will introduce a new advanced display for hand pallet trucks at the show. Main feature of this design is that the display is integrated in the handle of the hand pallet truck. Of course, this saves space. And at the same time, it significantly improves the ergonomics of the operator. For LogiMAT, our R&D engineers developed a prototype truck equipped with patented display on the handle technology. If you wish to see, touch, feel and experience this prototype with display on the handle, please do not hesitate to reach out to our sales managers and schedule a meeting for a live demo at LogiMAT.

Picking errors cause high, unnecessary costs, stock discrepancies and loss of customer satisfaction and superfluous communication. With the RAVAS order picking solution Pick by Weight you are always in control of every picking line during the complete order picking process.
With the RAVAS order picking solutions, all relevant information on the weight of your palletized flows is made available to any ERP or WMS in real-time, fast and efficiently. Pick by Weight is available with 1, 2 or 3 scales. Optimize order picking and save money. Stand C75, Hall 10

New and Improved IBC Bunds Range

Posted on by David Priestman

First Mats, Birmingham’s leading workplace products specialist, today announced the launch of their revamped range of Intermediate Bulk Container (IBC) Bunds. The company has expanded its offerings, providing customers with a more diverse and complete selection of products at significantly reduced prices. The new IBC Bunds fully comply with UK regulations and have a three-year guarantee on many products.

IBC Bunds are essential containment systems designed to prevent leakage and spillage of hazardous materials stored in Intermediate Bulk Containers. These containers are commonly used to transport and store chemicals, oils, and other potentially harmful substances. Bunds play a crucial role in minimising the risk of environmental damage and ensuring workplace safety.

“We are proud to present our new range of IBC Bunds, which offers our customers an even better selection of high-quality, compliant containment products,” said Richard O’Connor, Marketing Director at First Mats. “We have worked tirelessly to develop this new range that meets industry standards while offering significant cost savings for our customers.”

Customers can conveniently order their new IBC Bunds from the First Mats website (www.firstmats.co.uk) or by contacting the award-nominated sales and support team.

First Mats is a Birmingham-based workplace products specialist dedicated to providing high-quality products and outstanding customer service. With years of experience in the industry, First Mats offers a comprehensive range of products, including safety matting, and a wide variety of workplace essentials. The company is committed to ensuring the highest standards of safety and compliance for businesses across the UK.

Machine Vision Solutions for Logistics Automation

Posted on by David Priestman

Cognex will present machine vision-based solutions for automation in inbound, order fulfilment, sortation, and outbound areas at LogiMAT, the international trade fair for intralogistics solutions and process management, in Stuttgart, Germany, April 25-27th, 2023, at booth J11 in Hall 1.

To keep pace with increasing demands in order volume, item variability, delivery times, and order accuracy and tracking, customers are looking for solutions that enable more automation, reduce costs, and are easy to set up. At Cognex, the focus in product development is on standardised, easy-to-integrate solutions that offer flexibility and scalability and ensure that existing processes run smoothly even with high staff turnover.

The applications demonstrated at the Cognex booth cover all areas of logistics facilities. For example, in scanning applications of individual items, which are normally handled laboriously with handheld scanners, overhead mounted barcode scanners can greatly improve ergonomics and productivity. Cognex will also be presenting the new Modular Vision Tunnels at LogiMAT. These scan tunnels support barcode reading on packages at high speed and short gaps, providing a significant advantage to companies looking to increase sortation throughput and reduce processing times.
In addition to barcode reading, other types of inspections that can be solved with machine vision are opening up new applications.

Next Generation Logistics Facility

For order picking and sortation, for example, the 3D-A1000 item detection and dimensioning systems enables optimised use of totes, detection of package damage or open flaps, and proper identification for label application. Vision systems with embedded artificial intelligence-based tools are also becoming more pervasive in logistics. Applications can be trained with just a few sample images to reliably detect contamination on totes and sorting trays or to classify parcels and other objects.

Cognex is also presenting the High Speed Steerable Mirror (HSSM) at LogiMAT, a technology innovation that, in combination with the DataMan 470 barcode reader, allows for barcode scanning on large fields of view with a single compact system. The benefits are particularly evident with pallet scanning, where previously multiple fixed-mount readers were required, resulting in significant extra work for installation and maintenance.

Cognex Corporation designs, develops, manufactures, and markets a wide range of image-based products, all of which use artificial intelligence (AI) techniques that give them the human-like ability to make decisions on what they see. Cognex products include machine vision systems, machine vision sensors, and barcode readers that are used in factories and distribution centres around the world where they eliminate production and shipping errors.

Cognex is the world’s leader in the machine vision industry, having shipped more than 3 million image-based products, representing over $9 billion in cumulative revenue, since the company’s founding in 1981. Headquartered in Natick, Massachusetts, USA, Cognex has offices and distributors located throughout the Americas, Europe, and Asia.

Ravas Launches Weigh in Motion Tech

Posted on by David Priestman

Imagine a logistics process where you could weigh your palletized goods on the go. Or one where you consistently capture accurate weighing and dimensioning data in real-time without stopping. RAVAS can offer it all with Weigh in Motion technology. Visit RAVAS at booth S149 at ProMat and witness this technological revolution yourself.

Intelligent carriage plate with Weigh in Motion technology RAVAS USA has expanded its current range of iCPs, intelligent carriage plates, with Weigh in Motion technology. In the past, operators had to physically stop their forklift truck to capture the weight of a pallet. With RAVAS’ Weigh in Motion technology, you can weigh on the go without stopping or interrupting your logistics process. While driving at a consistent speed on a level surface, you can now generate reliable data on weight and volume in real time. The data can be transferred to any ERP or WMS and used to invoice your customers by weight. RAVAS’ Weigh in Motion technology is set to revolutionize supply chain optimization.

The RAVAS iCP is a proven, dependable product that enables you to weigh ‘difficult to pack’ products in combination with pre-construction equipment, such as a clamp or rotator. The iCP is available in wired or wireless models. Also, the iCP is NTEP certified to ensure you meet legal-for-trade requirements so you can invoice your customers by weight.

RPW EL scale for electric walkies and rider trucks

The revolutionary RAVAS RPW EL, a scale for electric walkies and rider trucks and order picking trucks, is available for every make and model of truck. Whether you are about to purchase one or more new trucks or you already own a fleet of trucks, our RPW EL solution is available for both retrofit and factory fit. To make a truck weighing, the fork construction of the truck is mechanically modified so that scale components can be mounted with only 5 mm extra fork height. Every lifted load is immediately weighed and communicated. Data communication and integration turns your order picking applications, supply chain optimization or production optimization into a true data collector. This data saves you time, money and obviously makes your processes more efficient and insightful.

iForks

The world’s first and most complete wireless forklift weighing fork sets, the RAVAS iForks can be quickly mounted on any forklift and immediately improve the efficiency of your logistics process. iForks improve crossdocking, weighing incoming and outgoing goods, and safely loading and unloading containers. The weighing system’s components are fully integrated into the forks, eliminating the need for additional cabling, that means installation on all makes of forklift trucks (new and used) is quick and effortless. The weight captured by the iForks is displayed on an indicator positioned in the forklift truck’s cabin. That information is then sent wirelessly via Bluetooth to your WMS. Available with both regular forks and extra thin forks, these weighing forks are powered by compact Lithium-ion batteries and come standard with Bluetooth 4.0 data transfer capabilities.

RAVAS manufactures and distributes mobile weighing solutions, integrated in hand pallet jacks, warehouse trucks and forklift trucks. Mobile scales enable you to weigh and measure your load during transport. Our connectivity solutions help you to improve logistics and optimize your supply chain.

Turnkey Solution de-palletizing Pallets to Trays

Posted on by David Priestman

With the launch of a new de-palletization system, Körber Supply Chain claims to be the first supplier of automated logistics solutions to offer a total turnkey solution for the separation of goods from pallet to tray. The goal is to fully automate and eliminate risks and sudden downtime in the sorting process.

New research shows that sudden stops and interruptions in the supply chain are the biggest concern for almost 90% of the companies surveyed within among others retail trade, consumer goods, and industrial production. This is one of the reasons why close to half of these companies expect to increase investments in strengthening their supply chain – including technology that ensures increased flexibility, transparency, and an overview.

To meet the market’s challenges, Körber Supply Chain has now, as the first supplier in the industry, developed a total solution to manage the sorting of products from pallets to trays. The solution is called Downstream. It is a de-palletizing system that separates each pallet layer into individual items, which can be turned and tilted to fit into trays and prepared for further distribution through a conveyor belt.

It is not straightforward to break down pallets into trays in a fully automated solution with the large variety of products handled by many companies. The overview is lost, when one mistake results in sudden downtime, creating an inefficient sorting process. Therefore, a reliable and durable automated logistics system was needed, which ensures higher productivity and stability and is future-proof in relation to new products, says René Kahr, Product Manager at Körber Supply Chain.

A complex operation in a simple system

The pallet to tray solution has been part of Körber Supply Chain’s portfolio for a few years, but the new version is a natural development by the tech company. The latest version is more intuitive and adaptable, thus decreasing potential downtime in the process. De-palletizing from pallet to tray is not affected by unique product packaging designs, slip sheets, or changes in the assortment, which are otherwise the classic culprits for errors and downtime.

When there are changes in packaging and assortments, problems arise in automated logistics. We now make the complex easy, and our system effortlessly sorts a pallet into smaller packages for distribution. In addition, the system can be integrated into other integrator solutions, while our software can be adapted to the individual distribution center’s quantities and sizes, explains René Kahr.

He explains that Downstream is estimated to be able to sort up to 2,400 items per hour, with sorted packages being redistributed and loaded onto a tray with one to six items on each tray.

The new solution builds on digital enablement

At Körber Supply Chain, one of the main goals is “digital enablement”. The goal is to help companies improve productivity and operations by implementing digital solutions. The pallet to tray solution is an AI-based solution that, with data tracking of the individual products throughout the entire process, 100% automatically transforms whole pallets into separate items on trays without manual intervention. The objective is to help to move companies towards a much more efficient operation.

There doesn’t exist a turnkey solution on the market about the redistribution from pallet to tray. With the new Downstream, we are closing that gap. It will help optimize operations, save resources, and remove uncertainty in an automated logistics process at distribution centers. The solution has already been sold to some of the leading players, so we know there is a need for the solution in several markets. The potential is high, says Ralph Korsbæk, Head of Sales of Product Solutions at Körber Supply Chain.

Nord Drivesystems Optimistic About Growth

Posted on by David Priestman

In a challenging year, NORD DRIVESYSTEMS also looks back on positive developments. Just before the turn of the years 2022/2023, the drive manufacturer passed the one billion euro sales threshold for the first time, increased its number of employees to 4,900 and opened new production locations worldwide.

“2022 was a very successful year, but at the same time characterised by crises”, says Gernot Zarp, Sales Manager at NORD DRIVESYSTEMS. “The customers’ feedback, however, was very positive as despite the bottlenecks in the supply chains we always tried to make everything possible for our customers.”

Focus topics and products

In 2022, the focus was mainly on innovative, energy-saving drive solutions to significantly reduce the energy consumption in industrial applications and to appropriately respond to the increasing energy costs – for example by using the patented DuoDrive and the high-efficiency IE5+ motors. The NORD ECO service supported companies in finding the most efficient drive solutions.

In addition, the NORD Group focussed on the topic sustainability: Internal processes have been made more efficient but also further aspects have been shifted into focus, such as environmental protection, the training and promotion of employees, human rights in the supply chain, certificates (EcoVadis and ISO 14001) and the signing of the UN Global Compact.

Investments and growth

In 2022, NORD DRIVESYSTEMS invested heavily in the extension of the capacities in Germany and abroad. The new office and administration building in Bargteheide was built, the production location in Yizheng, China, was completed and in the first quarter of 2023, the company’s fourth global assembly plant for industrial gear units will be opened in India to map the local growth. Furthermore, the manufacturer plans to extend the electronic production at its Aurich location, and to significantly increase the capacities of the motor factory in Poland.

Prospects for 2023

“The last years have shown that companies must position themselves more broadly. This is why the topic of Multisourcing will get a higher priority, especially in the fields of supply chain and production, but also in the global orientation of the target industries”, Zarp explains. In 2023, the focus will be on industries such as post & parcel, airport, warehouse logistics, bakery and packaging industry, and applications on bulk handling or mixing and agitating.

“Currently, energy-efficient solutions such as our patented DuoDrive and IE5+ motors are very popular as they provide a particular customer benefit. The same applies to our MAXXDRIVE® XD industrial gear units or the NORDAC ON frequency inverters, the power ranges of which we will expand to 3 kW”, says Zarp. Topics such as factory automation and digitalisation will also play an important role this year, particularly with regard to the growing Asian market.

“All in all, we look optimistically to the new year and assume a further improvement of the supply situation and further growth”, says Zarp. In the field of electromechanical motors and geared motors, the manufacturer is already back on pre-crisis level with its standard delivery times achieved and a reliability of more than 90%. “We all yearn for normality and stability instead of crises.”

Low-lift Pallet Truck Helper

Posted on by David Priestman

Clark has launched a new low-lift pallet truck for light transport tasks. The vehicle with the model designation LWio15 has a load capacity of 1500 kg and is suitable for short distances in goods distribution, production or in the warehouse. The vehicle is equipped with a long-lasting and powerful Li-Ion battery, which makes the LWio15 a reliable helper in industry, trade and logistics. Especially when a low-lift truck is only needed occasionally, the LWio15 is extremely cost efficient.

Compact and safe pallet truck

The LWio15 drives and lifts purely electrically. The operator can therefore operate the truck safely and ergonomically without any effort. With a length to the front of the forks (L2 dimension) of only 400 mm and an aisle width of only 1810 mm, the low-lift truck is extremely compact and manoeuvrable. Via a switch integrated in the ergonomic tiller, the truck can also be moved with the tiller raised. This makes the low-lift truck ideal for use in space-critical work areas and narrow aisles. Optional side support rollers prevent the vehicle from tipping and ensure stable and safe handling even when cornering. The LWio15 has a lifting height of 105 mm and is available with a fork length of 900 mm or 1500 mm, depending on the application.

Li-Ion battery guarantees high availability

The LWio15 is equipped with a 24 V (20 Ah) Li-Ion battery as standard and a storage compartment in which a second battery, also with 24 V (20 Ah), can be accommodated as an option. Intermediate charging, for example during breaks, can extend the vehicle’s operating time and avoid downtimes without limiting its service life. To charge the battery, the external charger included in the scope of delivery is simply connected to a 230 V socket. The battery can be quickly and safely removed from the side when it needs to be changed.

The operator also benefits from numerous advantages that have a positive effect on operating costs: Compared to the monobloc battery, the Li-Ion battery has a longer service life. There is no additional expense for maintenance work around the battery acid, as the Li-Ion battery is maintenance-free. Intermediate charging can be carried out without a special charging room, as no gases are released during charging.

Since the forklift was invented by Eugene Clark in Buchanan, Michigan (USA) in 1917, CLARK has been one of the worldwide market leaders in the materials handling vehicles business. With more than 100 years of experience in the materials handling vehicles sector and over 1.4 million forklifts sold worldwide, the CLARK brand, which is proud of its roots in America, is associated with modern and robust product design, progressive, sophisticated technology and excellent customer service. Since 2003, CLARK has been part of the South Korean Young An Group based in Bucheon and offers a complete product portfolio consisting of forklifts with electric power or internal combustion engines and load capacities of 1.5 to 8 tons, narrow-aisle forklifts, warehouse equipment and an extensive range of services.

CLARK Material Handling International (CMHI) with its head office in Bucheon, South Korea, is currently represented worldwide at more than 480 locations in over 90 nations. The operations are managed at four headquarters around the world. Production is assembled according to European quality standards at plants in Korea, the United States, Vietnam and China. With 170 Clark dealers in 60 countries, CLARK Europe GmbH is one of four subsidiaries of CMHI and serves the regions of Europe, the Middle East and Africa from its headquarters in Duisburg, Germany.

Mosca Showcases TechCenter at LogiMAT

Posted on by David Priestman

The main focus of Mosca’s appearance at this year’s LogiMAT from 25 to 27 April is on digitalisation and innovative service solutions. Stand 4D21 in Hall 4 is where the company will be using a tilt testing tool to offer insight into its newly opened TechCenter, in which customers can put their transport security systems to the test. Trade show visitors can also see live demonstrations of the new SoniXs TR-Connect, Mosca’s strapping machine designed for Industry 4.0.

“Mosca is much more than a machine manufacturer. We serve as professional partners for our customers’ sustainability and digitalisation projects,” explains Johannes Wieder, Sales Manager Logistics at Mosca. “And this is precisely what we want to demonstrate with our exhibit at LogiMAT.”

Mosca will not only be presenting its own machines at the trade show this year. Live demonstrations using a tilt testing tool will enable visitors to see quality checks on strapped products first-hand. Although the special machine is not part of the Mosca portfolio, it has been integrated into the company’s new TechCenter. This high-tech test lab in Waldbrunn enables customers to subject their cargo units and transport security systems to various stress tests and optimise them for sustainability as well as resource efficiency.

Wieder explains: “Many companies don’t notice that their transport security isn’t capable of withstanding high loads until the worst-case scenario occurs. This is why we developed the Mosca TechCenter as a service solution. Our customers can check a wide variety of load units and influencing factors to make adjustments to their packaging before the worst case occurs. Our display at LogiMAT gives customers initial insight into how the Mosca TechCenter operates.”

Strapped product pallets are placed in the tilt testing tool at the Mosca stand and tested for transport security. The machine tips the pallets to a predefined angle to test the stability of the bundled load when it is tilted. “Customers can run a full range of tests in our TechCenter: from acceleration and vibration to impact and crushing force testing,” Johannes Wieder explains. “The Mosca TechCenter is fully equipped to ensure customers can conduct tests that are most relevant to their transport processes.”

SoniXs TR-Connect introduced as Mosca’s new Industry 4.0 machine

Along with the introduction of the Mosca TechCenter, the market launch of the new SoniXs TR-Connect will also take place at LogiMAT. The basic principle of this high-tech machine is well established: Mosca is combining two previous models, the SoniXs TR-6 Base and TR-6 Pro, into the TR-Connect. Mosca innovation manager Andreas Ding explains the changes: “The new TR-Connect gives our customers more flexibility when it comes to further developing and networking their packaging lines. In the past, users who opted for a SoniXs TR-6 Base but later needed the functions of the Pro version had to replace the entire machine. The new TR-Connect can be easily adapted at any time and comes with all the functions that users need for Industry 4.0 applications.”

Key features include an integrated WebHMI that enables users to view all performance-related machine data, like availability and quality, at any time. The interface also makes commissioning and operating the SoniXs TR-Connect much easier because the machine can be remotely monitored at all times. An optional OPC/UA interface enables even greater flexibility. Thanks to compliance with the communication standard, the TR-Connect can be easily connected to a wide variety of interfaces to share information. Other options include the Mosca Digital Package, which makes it possible to use a tablet computer for easier machine adjustments.

Automated Bagging System for Totes

Posted on by David Priestman

An automated packaging solution – provided by distribution partner Yorkshire Packaging Systems (YPS) using Hugo Beck’s flexo e-com machine – has helped totes ISOTONER (UK) to fulfil five times its previous daily order capacity in the run up to Christmas.

totes ISOTONER is a large fashion accessory company, with operations in North America, the UK, Scandinavia and throughout Europe. With a product range featuring the original totes toastie slipper-sox (socks with slip-resistant soles) plus gloves, scarves, slippers, umbrellas, wellies and sheepskin boots, the well-known accessory, gift and footwear brand is stocked in stores across the UK and also runs a B2C e-commerce service, shipping daily online orders out direct to customers’ homes.

The run-up to Christmas 2021 was a particularly busy season for totes’ warehouse and office facility in Billericay, Essex, prompting the company to automate its packaging processes. Prior to the recent investment, totes’ dispatch of orders involved a manual pick and pack process whereby goods were loaded by hand into a choice of three different sized, pre-formed, loose mailing bags. This process often proved problematic, particularly during peak periods, when demand would outstrip physical capacity.

In the first quarter of 2022, totes approached YPS in need of an automated machine, capable of achieving target speeds of 720 packed bags per hour – equating to 12 packs per minute. In addition, the solution proposed needed to sync with their existing ERP systems and allow totes to reduce their reliance on Royal Mail’s data system by including high-speed and GDPR compliant courier label printing.

“To measure up to totes’ needs, YPS recommended the horizontal Hugo Beck flexo e-commerce automatic bagging unit, with an internally mounted VULCAN direct apply labeller from Clearmark,” says Tom Hill, Sales Manager at Yorkshire Packaging Systems. “Hugo Beck’s solution is tailored specifically to coping with the demands of a busy e-commerce packaging line, with its high-speeds, high volume and data security. Replacing totes’ original grey mailing bags with precise-fitted packaging, the machine is able to accommodate over 95% of totes’ product range, from single pairs of socks right up to boxed pairs of wellies. It is this responsiveness to product dimensions which makes the flexo e-com system ideal for totes’ dynamic, busy warehouse. The production does not need to be batched,” explains Hill.

Furthermore, to maintain totes’ brand consistency, YPS were able to replicate the plastic film used on the new line with the original preformed bags by colour matching the shrink film, thus creating durable, 525mm 50mu polythene which is 100% recyclable with a 50% post-consumer waste blend.

The machine scans each order’s unique printed barcode and the correct customer address label is seamlessly recalled by the VULCAN. The length of each product is also detected and the flexo e-com machine then tailors the bag length to precisely match, resulting in a snug finished pack and minimised material usage. The bag width can also be adjusted on the fly with a simple wheel winding mechanism. Before destroying the data in a one in, one out method, translating to complete security and GDPR compliance for totes, the label is applied to each bag via an all-electric system using continuous motion of the VULCAN – significantly increasing the line speed compared to stop-start application models. Furthermore, there is no need for compressed air supply and pneumatic parts which can both require regular maintenance.

Since installation, totes reports that the new e-commerce line has entirely overhauled its UK operation. Far outstripping the target speeds of 12 packs per minute, at sign off the solution achieved an impressive speed of 18 packs per minute and 1080 packs per hour – a daily order output five times greater than pre-install.

“Investing in this equipment from YPS has proven to be a gamechanger,” commented Karl Blackburn, Operations Director at totes ISOTONER (UK). “We’ve radically increased our throughput, allowing us to complete more online order despatches in a faster timeframe and please more of our customers,” concluded Karl Blackburn. “The support offered by the team at YPS has been second to none; every technical query has been answered and resolved quickly and professionally, allowing us to run at peak performance.” Based in the United Kingdom, YPS is part of Hugo Beck’s extensive global sales partner network with dedicated sales representatives all over the world.

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