Executives are under pressure to improve profitability, even as rising costs and labor challenges shrink their margins.
One way to achieve more profit is to increase throughput, but that tends to put more strain on operations and is hard to sustain with labor shortages and turnover. The more effective solution? Packaging automation.
Many organizations have started to outgrow the standalone packaging equipment that once proved effective. By modernizing packaging lines, organizations can reduce their reliance on labor while improving speed, consistency, and output. At Shorr, we’ve implemented packaging automation that not only cut costs but also drove long-term profitability, regardless of company size.
Automated packaging systems can be a great strategic advantage. That’s why we want to help organizations determine the right time to upgrade their systems and know what to expect during the process.
How Automated Packaging Can Become a Profit Center for Your Business
Manual or outdated packaging systems can become a barrier to growth. They can lead to inconsistent throughput, higher error rates, material waste, a heavy reliance on labor, and limited scalability. All of these issues make it difficult for organizations to keep pace with demand.
By contrast, automation enables faster order fulfillment, higher volumes without additional headcount, and improved consistency. It also supports sustainability goals by reducing void fill usage and right-sizing packaging.
Packaging automation has evolved from rigid, one-size-fits-all options to cutting-edge modular solutions for your specific needs. We are utilizing technologies like collaborative robots, known as “cobots.” These service robots boast a variety of safety features and can augment your human workforce by completing dangerous or unergonomic tasks. The combination of innovative technology and industry-leading ideas adds value to operations and supply chains through streamlined processes and cost-saving efficiencies.
Real-world results emphasize just how powerful the shift to automation can be for an organization’s bottom line. In one example, a food company working with Shorr wanted to double its production through packaging automation. At the time, employees were manually erecting, taping, sealing, and labeling cases. Shorr’s automation experts replaced these manual processes with a conveyor system that delivered cases to employees for packing, then automated the closing, sealing, and labeling. This new system increased production by 120% and enabled the company to reallocate employees to other key areas of operations.
An agricultural manufacturer saw a similar result when it engaged Shorr to increase line speeds and automate sorting to boost output. After a thorough audit of their current packaging processes, we developed a new packaging line layout that reduced hand-packing and enabled palletizing master cases. This approach increased line speeds by 73% and doubled production volume. Automation has the power to solve real business needs and enable strategic growth.
When to Consider Packaging Automation
One clear signal it’s time to automate is when labor costs and overtime expenses rise faster than revenue. When this happens, adding people or hours simply isn’t going to increase throughput effectively. Packaging automation allows you to control costs while also increasing throughput.
Peak demand reveals challenges for many organizations. Inconsistent throughput, missed SLAs, difficulty hiring or retaining packaging operators, and excessive rework, waste, or quality variability are all opportunities to scale automation more effectively. Automation improves consistency without an overreliance on labor.
In other cases, physical or strategic constraints uncover pain points in an existing system. Limited floor space can prevent manual scaling, while packaging changes driven by sustainability or eCommerce requirements may not work within the current lines. Automation offers flexibility that works within the current system but also enables strategic initiatives.
Customized End-to-End Efficiencies
The reason we don’t take a one-size-fits-all approach to automation is that every organization’s products, facilities, and business goals are unique. Upfront auditing and planning are the best tools to evaluate current processes and identify inefficiencies. From there, it’s all about selecting the right layout, equipment, and materials to eliminate bottlenecks and help you grow.
Some companies delay automation discussions, believing their operations are too simple or complex to benefit. In reality, automation can make a difference regardless of your size or setup. We can create a seamless solution ranging anywhere from primary packaging to case packing and conveying, through stretch-wrapping pallets for transit. Shorr can partner with you to modernize packaging in a way that meets the needs of today’s volume, while planning for tomorrow’s demand.
A successful packaging system integrates machines and equipment into one cohesive line. Shorr partners with top manufacturers to supply the most effective solutions on the market and then trains your team on how to use them. We cover the entire packaging process, including all-electric bagging machines and strapping, banding, and tying systems that help reduce product damage. You can also call on Shorr’s factory-trained and certified technicians for a range of packaging equipment repair services to minimize downtime.
What to Expect When Activating an Automated Packaging Line
We understand that keeping packaging systems running is vital to your business, which is why automation rollouts are carefully coordinated to limit disruptions. We also recognize that you need a system that can adapt as business requirements change, ensuring that your lines are scalable. To ensure a smooth rollout, we craft a detailed plan with flexible line designs and a deliberate approach to integrating automation equipment into existing operational systems.
Our team of experts will be with you throughout the entire process. They understand how the latest technologies can serve your business and can create a project plan that maximizes your output and increases profitability. Once equipment and materials are in place, our team tests and optimizes each step to ensure we achieve the expected results. Ongoing service, preventative maintenance, and parts are also available so your team can stay focused on daily operations.
Ultimately, organizations that invest in automation do more than just improve efficiency. They turn packaging operations into a profit center. The right partner can position your organization to overcome market and labor challenges, ensuring you stay ahead of the competition.