Packaging 101

Tag: Case study

Case Study: AUTOBAG 850S Mail Order Fulfillment

Posted on by Brendan Ploen

This customer case study example comes from one of our suppliers, Sealed Air.

Improving Operational Efficiency for Online Retailer, Fanatics

The Challenge:

Delivering to over 180 countries, Fanatics is a global supplier of sports fan merchandise including football shirts, shorts, socks, baseball caps, mugs, and other souvenirs. The online retail giant supplies consumers worldwide with official merchandise from some of sports’ biggest names. Those teams include Manchester United, Dallas Cowboys, and England Rugby. 

From its warehouse in North Manchester, an average of 7,500 packs are shipped every day to meet demand from its hugely popular website. During the holiday peak season, order volumes increase to four times the average amount. The majority of Fanatics packaging operation was handled manually. It put a strain on labor resources and can slow down order fulfillment. Packers worked at eight pack stations manually filling and sealing bags by hand. Afterwards, they then printed labels and invoices on two printers.  

Fanatics needed a bagging and printing packaging system that would optimize existing resources. Those include labor and warehouse space, and streamline its complex, high-volume e-commerce order fulfillment processes.

The Solution:

The AUTOBAG® brand 850S is a high-speed bagging and printing system uniquely designed to provide enhanced packaging productivity for mail order fulfillment and e-commerce applications. “The main reason for installing the machines was to save space while allowing us to meet some fairly ambitious growth targets,” said Andrew Crozier, Fanatics Operations Manager. 

As a result, with the help of four AUTOBAG brand high-speed bagging and printing systems, Fanatics has increased its capacity to keep pace with fulfillment demands. Additionally, the company was able to eliminate most of its manual pack stations and can now process five times the number of orders per hour with the same amount of resources. In addition to optimizing labor and warehouse space, the AUTOBAG brand 850S improves the packing process with its built-in printer that allows the label to be printed directly on the bag for better labeling of soft goods or oddly shaped items.

Results:

Due to the steps taken, here are the findings of the case study:

  • Increased efficiency and throughput velocity by 5X
  • Reduced the number of manual pack stations
  • Optimized existing labor and warehouse space
  • Ability to scale fulfillment operations to accommodate peak season and changes in demand

Evolving Automation For E-Commerce Fulfillment

To continue advancing automation for e-commerce, Sealed Air launched the AUTOBAG brand 850S paper high-speed bagging and printing system. This sustainable solution runs all-paper bags that are curbside recyclable while continuing to deliver efficiency and throughput for fulfillment operations.

Furthermore, to learn more about the AUTOBAG 850S Bagging System, click here.

Pyramid Packaging is a proud supplier of the AUTOBAG 850S. To inquire more about the machine or this case study, feel free to contact us using this link. You can also email us at [email protected].

Autobag 600 Wide Bagging System Case Study

Posted on by Brendan Ploen

For maximum productivity in wide bag and horizontal packaging applications, the Autobag 600 Wide Bagging System provides versatile packaging capabilities for not only mail order fulfillment, but of larger items, too. In this case study and application, two systems were installed to maximize productivity because of this rapidly growing business and industry. To clarify, United States Postal Service-approved mailbag sizes range from 16″ wide by 27″ long.

The Autobag 600 wide mailbag system prints and packs up to 10 bags per minute. As a result, this has reduced the number of employees from five to two, more than doubling productivity.

Annual savings: $85,160

Product shipped: Collectibles

Payback period: 11 months

Previous method: Handloading into flat bags

Previous Labor: 5 employees

Previous Cost/1000: $213

New method: Two Autobag Wide Baggers

New labor: 2 employees

New cost/100: $128

Typical applications for this bagging system include, but are not limited too: Aerospace & Defense parts, Apparel & Accessory Packaging, Automotive parts, Electronic parts, Hardware & Fasteners, Healthcare, Hobby & Craft, Household Products, Personal Products, Pet Products and Toys.

Pyramid Packaging is a proud supplier of the Autobag 600 wide bagging machine from Sealed Air. To learn more, click here to fill out a Contact Us form. You can also reach out by giving us a call at (847)-272-3400, or sending us an email at [email protected].

Autobag PS 125 OneStep Tabletop Bagger

Posted on by Brendan Ploen

The Autobag PS 125 OneStep tabletop bagger is a compact automated packaging system designed to improve packaging speed, consistency and productivity without requiring a large production footprint. Ideal for fulfillment centers, medical manufacturers, retail packaging and industrial applications, the Autobag PS125 combines reliable bag feeding, sealing and optional inline printing in one easy-to-use tabletop machine.

With fast setup, intuitive controls and dependable performance, the PS 125 helps reduce manual labor while improving packaging quality and operational efficiency.

Why Choose the Autobag PS 125 OneStep?

The Autobag PS 125 is designed for businesses looking to automate hand-loading operations without investing in a full-size bagging system.

Benefits include:

  • Compact tabletop footprint
  • Fast bag loading and sealing
  • No compressed air required
  • Optional integrated thermal transfer printer
  • User-friendly touchscreen controls
  • Reliable AutoBag bag feeding technology
  • Consistent package quality
  • Reduced labor costs
  • Easy changeovers
  • Ideal for low- and medium-volume production

PS 125 Specifications

SpecificationValue
MachineAutobag PS125 OneStep
SpeedUp to 15 bags/minute
Standard PS125Up to 25 bags/minute
Bag Width2″–10.5″
Bag Length4″–17″
Film Thickness1–4 mil
Electrical100–240 VAC
Compressed AirNot Required
PrintingOptional Integrated Printer
The Autobag PaceSetter PS 125 OneStep is a compact, tabletop bagger ideal for mid-volume fulfillment operations. In this application, the built-in imprinter is used to interface with a database for printing order information, address, and barcodes directly onto the mailbag. This semi-automatic system replaces the need for separate printing and hand-affixing labels and produces up to 15 packages per minute. The costs for materials and postage are reduced.

How the PS 125 Works

The Autobag PS125 uses pre-opened bags on a roll to automate the packaging process. Operators simply load the product into the open bag while the machine automatically indexes the next bag, seals it and prepares the following package.

The OneStep version integrates bag printing directly into the packaging cycle, eliminating secondary labeling operations while improving traceability and production efficiency.

Applications

The Autobag PS 125 OneStep is commonly used for:

  • Ecommerce fulfillment
  • Medical devices
  • Pharmaceutical products
  • Nutraceuticals
  • Hardware & fasteners
  • Automotive components
  • Electronics
  • Retail packaging
  • Consumer products
  • Replacement parts
  • Promotional kits

PS 125 vs. Manual Bagging

Compared with manual bagging, the Autobag PS125 offers significant productivity improvements.

Manual BaggingAutobag PS125
Slower packagingUp to 25 bags/min
Inconsistent sealsConsistent heat seals
Higher labor costsReduced labor requirements
Manual labelingIntegrated printing available
Variable qualityRepeatable packaging quality

Companies that automate with the PS125 often reduce labor while increasing throughput and improving package consistency.

Proven Customer Results

One Pyramid Packaging customer reduced packaging labor from ten operators to one after implementing the Autobag PS125 OneStep.

The project delivered:

  • $212,500 annual savings
  • Six-month payback period
  • Reduced shipping costs
  • Improved packaging consistency
  • Higher production throughput

For the complete implementation story, read our PS 125 Tabletop Bagger Case Study.

Why Buy Your Autobag PS125 from Pyramid Packaging?

Since 1968, Pyramid Packaging has helped manufacturers improve packaging efficiency with automated bagging systems, flexible packaging materials and expert engineering support.

Our team can help you select the right Autobag machine, bags and accessories based on your production requirements.

FAQ

What is the Autobag PS125?

The Autobag PS125 is a compact tabletop automatic bagging machine designed for hand-load packaging operations.

What’s the difference between the PS125 and PS125 OneStep?

The OneStep model includes an integrated printer that prints each bag before sealing.

How fast is the Autobag PS125?

The standard PS125 runs up to 25 bags per minute, while the OneStep model operates up to 15 bags per minute.

What industries use the PS125?

Medical, ecommerce, food, nutraceutical, industrial, automotive and retail manufacturers.

Does the PS125 require compressed air?

No. The machine operates without compressed air, simplifying installation.

Pyramid Packaging is a proud supplier of the Autobag PS-125 OneStep bagging machine from Sealed Air. To learn more, click here to fill out a Contact Us form. You can also reach out by giving us a call at (847)-272-3400, or sending us an email at [email protected].

Case Study: Loveshaw CF-5 Case Former and LD-3SB Case Sealer

Posted on by Brendan Ploen
Loveshaw Case Study – CF-5 Semi-Automatic Case Former & LD-3SB Case Sealer.

An authorized Little David distributor was asked to visit a national co-packer to evaluate the benefits of a box former and a case sealer. The company was interested in increasing throughput by eliminating the existing manual process. Previously, the operators were hand erecting and bottom taping the box, inserting a partition, placing 4 pouches of product in the box and manually sealing the top of the box.

The equipment proposed needed to be mobile. It would also be moved frequently for use in multiple lines, but had to be operator-friendly for frequent case size changes. In coordination with Loveshaw, an onsite demonstration of the CF-5 with LD-3 SB extended drive case sealer with three flap folder was conducted at the facility. Therefore, a case study was created.

The Challenge

1. The manual process of erecting and bottom sealing was both slow and inefficient.
2. The weight of the product was also heavy; 18-20 lbs. per pouch with 4 pouches in a carton. The machine needed to be industrial grade.
3. The top sealing was equally slow and inefficient.

The Results

Firstly, the CF-5 secured and squared the case. Next, the operator inserted the partition, and placed the pouches into the box. Finally, the operator was only required to tuck the rear minor flap and the LD-3SB with 3 flap folder, folding the remaining flaps then top and bottom to seal the box. Following the results, the manager noted a 66% increase in throughput on the line because of the investment in Little David equipment.

To provide maximum use for the machinery in the facility, quick release brackets and castors were installed, therefore, the customer could use the LD-3SB on other production lines when not running the pouch line. As a result, the combination worked out well for the customer and they are impressed with the robustness and consistency of the Loveshaw system.

Following the case study, here’s an additional look at the performance features of the CF-5 and LD-3SB.

CF-5 Performance Features:

1.PLC driven: monitors and controls each step in the flap folding process providing precise and therefore repeatable sequence
2. Three points of safety: all three photo eyes need to be blocked at same time to activate
3. Operate from either side
4. No lubrication needed
5. Made with heavy duty steel and stainless steel
6. Case range: Length: 8″ – 26’5/ Width: 5″ – 20″/ Height: 3″-  inf. Narrow box option of 3.5″
7. Compact Footprint: Length: 44″ /  Width: 34″ /Height: 33″
8. Speed: operator dependent
9. 110 VAC, 60 Hz single phase, 2 Amp
10. Air requirements: 6.5 SCFM

LD-3SB Little David Performance Features:

1. Speed: 76 fpm
2. Case Range: Length: 3 – Inf / Width: 4 – 20 (narrow box option of 3″) / Height: 4″ -24″ (high mast option up to 34″)
3. Compact Footprint: 32″ x 33″ x 59″
4. Easy to operate
5. Single mast design for safety, quick, easy case changeover: slide and lock height and width wheel adjustment
6. Durable: Built with not only heavy gauge steel to last in the most demanding 24/7 operations, but also front and rear horizontal leg braces for added stability
7. CAC60 Case Locker Tape Cartridge with five patented features

To find out more, we have a range of case sealers and case formers available, or feel free to reach out via email at [email protected], as well as filling out a Contact Us form. You can also call us at (847)-272-3400.

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