Driving Throughput: Your Guide to Getting the Most Out of Automated Bagging Equipment

As part of our Driving Throughput series, this month we are exploring why choosing a bagging solution with packer-centric design improves ergonomics, workforce safety, and production flexibility, ultimately driving productivity. We caught up with David Schuda, Vice President of Technology at Pregis to understand the full impact.  

How Equipment with Operator-Inspired Design Drives Better Throughput 

As we look ahead to 2024 and beyond, ecommerce is projected to grow by double digits as demand for the seamless fulfillment of products continues. For retail and logistics businesses alike, implementing packing automation, like Automated Mailing and Bagging Solutions, is the key to achieving throughput KPIs. But in order to truly realize those output goals, it’s important to recognize the role your operators play in the automated bagger process. Selecting a solution that was designed from the ground up with users in mind is crucial.  

“A packer-centric design in machinery is so important to create a truly efficient and valuable piece of equipment, it’s really part of thinking through the entire design process end to end,” explains Schuda. “We observe how the facility uses (or would use) the machine, the issues that are arising in their current situation, and then we go about deciding how to solve their challenges. We want to create something that truly makes their processes stronger and faster, not one that solves one problem while adding more to a customer’s plate.”   

Whether it’s in a 3PL or a large ecommerce warehouse, manual fulfillment is cumbersome to even the most productive employee. “Packers have to reach for the item and place it on the workstation, retrieve the mailer, scan the item, insert the product into the mailer, manually seal it, print the label, apply the label, and finally place the packed mailer on the conveyor label side up. And it all has to be done in proper sequence, preferably quickly.” explains Schuda. With the right automated solution incorporated, the steps are drastically reduced. The worker scans the item, places it into the bag, and presses a button to cycle the machine to the next mailer. “Generally, you can get 3-4 times the throughput versus manual packing. But that is only if you’ve got your equipment working with your people and not against them.” says Schuda. 

But not all automated baggers are designed the same. So what should you consider when looking to add a bagger to your operations? We’re happy to help. 

Comfort is Key 

Believe it or not, ergonomics can have a big impact on throughput. Incorporating a bagging machine that adjusts to an employee’s height or has a Human Machine Interface (HMI) screen that swivels side to side to accommodate worker preference can prevent the strains and sprains that can accompany repetitive motion. Comfortable works are a huge asset for a warehouse when it comes to keeping up high-volume operations.  

As an engineer, Schuda explains “purpose-built machines” consider every step of the packing process, working to remove unnecessary motions like walking too far around the workstation to get supplies or awkwardly reaching and twisting for products. “An ergonomically designed, purpose-built machine takes into account the position and height of the machinery, the orientation of the package on the belt, and the placement of the conveyor that takes the package away to the fulfillment center,” says Schuda. Making small adjustments in the equipment design can reduce the body strain that zaps workers’ energy and vitality, improving overall productivity.  

Help Increase Output with Inherently Safe Products  

While worker comfort is important, worker safety should be your number one concern when incorporating new equipment into your warehouse.  

Automated baggers are made to be easy-to-use, but that doesn’t mean there’s no risk to employees. There’s always the risk of hands or arms getting pinched in the bagging mechanism. That is unless your bagging machine is designed to be inherently safe.  

A low-force jaw mechanism with built-in sensors that won’t close on a worker’s hands or arms are a must when looking for a new bagging machine. These features mean that when a packer places a product into a mailer, they don’t need to worry about a potential injury from the seal bar closing because if there’s an obstruction, the bar won’t close.  

Keeping your workers safe is the most important thing you can do to ensure that your processes are efficient.  

Thoughtfully Designing for Optimum Efficiency 

One of the biggest challenges – or at least the cause of consternation – is integrating automated baggers within established footprints. Bringing in a new piece of equipment that adds new processes on top of existing ones, isn’t helpful in creating a productive warehouse environment.  

When bringing in a new piece of bagging equipment to an existing space, consider partnering with a manufacturer whose equipment was designed with the ability to fit into your space. To make that situation even more ideal, look for a supplier that can support your installation through a strong applications engineering team willing to come onsite and get your new bagging equipment working alongside your existing equipment, people and processes.    

“A bagging machine isn’t necessarily going to drive efficiency if everything has to change around it. That’s why it’s key to look for a product that compliments the way your warehouse is set up.” Schuda says.  

A Portfolio That Has It All 

Interested in checking out our line of Pregis Sharp™ automated bagging equipment, all of which have been designed with packers in mind? We'd love to help answer your questions about driving throughput throughout your operation.