I-Pack and Ultipack Packaging Systems from Sealed Air Automation

Pick and pack distribution centers and fulfillment operations can completely – and easily - automate secondary packaging with the I-Pack ® and Ultipack ® packaging systems from industry leader Sealed Air. These packaging systems are highly versatile and flexible, and offer a host of benefits, including –

• Reduction or elimination of void fill materials
• No capital investment for packaging equipment
• Better looking, stronger, and tamper evident packages

I-Pack and Ultipack Packaging Systems Use Three Modules

• Tray Forming Module
• Void Elimination Module (I-Pack)
• Void Containment Module (Ultipack)
• Lidding Module

Ideal Packaging Systems for Pick and Pack Distribution

Both packaging systems are designed to run 24/7/365 in high volume, pick and pack distribution centers. I-Pack and Ultipack are used worldwide to package a wide variety of items, including –

• Books
• CD and DVD
• Consumer Electronics
• Cosmetics
• Industrial Supplies
• Lamps
• Luxury watches
• Office Supplies
• Pharmaceuticals
• Video Games

The 3-Step I-Pack Packaging Production Process

Like most breakthrough technologies, the I-Pack System is simple.

• Corrugated trays of virtually any size are formed in the Tray Forming Module and fed into the picking line.
• Once filled, trays are conveyed to the Void Elimination Module, where the tray sides are scored and folded down to the exact height of the contained item(s).
• Trays are then conveyed to the Lidding Module, where a lid is automatically placed and glued.

By eliminating void fill packaging materials, I-Pack reduces shipping volume by 30% on average, improving shipping efficiency and reducing in fuel consumption during transport.

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The 3-Step Ultipack Packaging Production Process 

In addition to being highly efficient, the Ultipack void containment process is much simpler than alternative automated case erecting and void fill options.

• Corrugated trays of any size are formed in the Tray Forming Module and fed into the picking line.
• Once filled, trays are conveyed to the Void Containment Module, where a corrugated wedge is automatically inserted and secured around the tray’s contents, eliminating the need for additional packaging materials.
• Trays are then conveyed to the Lidding Module, where a lid is automatically placed and glued.

The corrugated wedge gives the package additional strength and provides flexibility for operations where package contents vary  in size, shape, and fragility. 

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Benefits of I-Pack and Ultipack Packaging Systems

Operations and Engineering

• Systems allow pick and pack operations to calculate the exact cost of each shipping unit. 
• Ergonomics – Trays are far easier to fill than RSC style corrugated boxes.
• Flexibility – Systems are modular and can be integrated with virtually any packaging line configuration.
• Versatility – Shipping units can be fully customized to meet precise requirements for size, product stabilization/protection, opening style, and other factors.
• Sustainable Packaging – Both packaging systems are designed to run lightweight corrugated board and eliminate inner packaging materials and sealing tapes.
• Reliability – Engineered for 24/7/365 use
• Extended packaging automation – The systems provide a platform for automation in other areas, including carton coding and print and apply labeling.
• Elimination of SKUs – Corrugated boxes, inner packing materials, and tapes.
• No WMS reconfiguration necessary.
• Reduction in transportation costs due to minimizing weight and cube.

Purchasing and Procurement

• No capital investment required – Customers pay a usage fee only.
• Elimination of inner packaging materials and carton sealing tapes.
• Reduction in corrugated material cost when lighter weight board and smaller sizes are utilized.

Sales, Marketing, and Branding – Consumer Satisfaction

• Systems produce highly attractive, high strength, and unique shipping units.
• Strong tamper evidence characteristics.
• No scissors or knife required for opening.
• Shipping units are eco friendly – returnable, reusable, recyclable.
• Catalogs or other inserts can be placed on top of the corrugated wedge with the Ultipack system.

I-Pack and Ultipack can be integrated with all ERP/WMS system software and any warehouse equipment, including conveyors, printers, scales, and sorters. The systems can also operate in stand-alone mode.

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