Packaging automation uses advanced hardware and software to automatically create, pack, and seal boxes based on each order’s dimensions. Instead of relying on pre-made box inventory, the system measures or receives digital data about the product and cuts corrugate in real time to create a right-sized box.

Right-sized packaging on demand means producing a custom-fit box for every order exactly when it’s needed. It eliminates empty space, excess filler, and the waste associated with stock box inventories.

Traditional methods rely on pre-set box sizes, forcing packers to overfill with void material or ship unnecessary air due to lack of customization. Right-sized packaging uses real product data to make a perfectly sized box in seconds. This process reduces corrugate use, shipping costs, labor needs, and carbon footprint for every order.

While automated packaging solutions vary in complexity, the two most common components include a packaging machine to create the box and packaging software (such as PackNet) to tell the machine what size box to create. Additional components include optional integrations with Warehouse Management Systems (WMS) or Enterprise Resource Planning (ERP) systems for fully connected workflows, which include more advanced use cases like shipping label application.

Packsize systems are compatible with most single-wall, double-wall, and select heavy-duty corrugate grades in fanfold (z-Fold®) format.

Throughput depends on the packaging system. The throughput of our systems ranges from 240 boxes per hour to over 1,500 for fully automated, high-volume fulfillment.

Box dimensions vary by machine. Some of our systems can make boxes under 1 inch in height to fit through an envelope slot, while our large-format systems can create boxes big enough for bulky items like couches, cabinets, and garage doors.

Packsize machines can produce many different FEFCO styles, including RSC, FOL, OPF, trays, and complex custom designs optimized for specific products or shipping needs.

Anything from apparel and electronics to furniture, appliances, building materials, and heavy industrial parts.  The system adapts to both lightweight and bulky items. Right-sized packaging also provides extra protection for fragile items such as glassware.

Yes. Packsize solutions can process both single-SKU and mixed-SKU orders, automatically determining the optimal box size and type for each with advanced logic.

There are several ways boxes can be created. Box dimensions can come from product level or order data sent from the customer’s WMS, barcode scanning, dimensioning systems, or operator input.

The right solution should be based on your product mix, shipping volume, integration needs, and warehouse layout. Packsize assess your operation, data, and workflow and recommends the best system configuration. Your solution could range from a single packaging machine to a mix of machines to create an optimized packaging workflow.

Manual packaging may suit low-volume non-complex operations, but automation becomes cost-effective when throughput and order variability increase. Automated processes can also help solve labor challenges, improving labor optimization and employee satisfaction.

Absolutely. Packsize’s high-speed systems are built for large eCommerce and distribution centers shipping anywhere from 10,000 to over 100,000 boxes per day—keeping pace with the most demanding operations.

Yes. The PackNet Software Platform integrates with any WMS or ERP system to synchronize order data and automate production. Our software integration engineering team specializes in helping customers integrate Packsize solutions into their unique environments.

By eliminating void fill and reducing box dimensions, automated packaging cuts dimensional weight (DIM) fees and damage rates, and optimizes truck and pallet utilization.

Right-sized packaging reduces corrugate waste, carbon emissions, and non-sustainable void fill materials. Based on our data, many customers reduce corrugate use by up to 30% and CO₂ output by up to 20%.

It removes the need for over-boxing and filler materials, using exactly the amount of corrugate required for each shipment with the optimal design, avoiding material waste and obsolescence.

A tighter, custom fit minimizes product movement inside the box. Custom box designs with protective material create added protection for bulky or fragile items. These approaches significantly reduce shipping damage and returns without the added costs and inefficiencies of stock boxes and excess void fill.

The PackNet Software Platform provides real-time dashboards and reports showing corrugate usage, box production rates, and sustainability metrics such as CO₂. It also shows freight savings that can be leverage into customer specific reporting systems.

Packaging as a Service is Packsize’s end-to-end solution approach that combines equipment, software, materials, and service into one managed subscription. This approach allows you to easily scale up and down without taking on CapEx or asset ownership risks that make it harder to respond as your operation changes.

We provide 24/7 technical support, remote monitoring, preventive maintenance, on-going operator training, and solution optimization services.

Packsize machines are built for industrial environments and are designed to meet the rigorous requirements of high-throughput workflows. Customers have consistently achieved 10+ year lifespans with regular maintenance and upkeep.

Packsize machines require routine cleaning, component inspection, and scheduled routine service. Most customers pair this with our proactive maintenance program to minimize downtime and increase longevity.

Cost varies based on volume, machine type, and integration complexity. Packsize customizes solutions for each operation’s size and goals with financial options like Packaging-as-a-Service or CapEx based on preference.

While payback varies based on solution and usage, most customers see payback within 3–24 months through labor savings, corrugate reduction, lower freight costs, and improved productivity.

Contact us or submit a request through our website. An expert will review your operation and create a tailored proposal and solution design.

Yes. We provide multiple purchasing, leasing, and service models to align with your capital and operational budgets.

Primary factors include production volume, required material or design requirements, integration needs, level of automation, and facility layout.

Safety interlocks, light curtains, emergency stop systems, and software controls ensure operator and equipment protection along with operator PPE standards.