The Perfect Fit Part 2, Packaging Solutions for Labor Shortages

tensionapdev on July 6, 2022

Labor shortages continue to challenge warehouses, but automation offers a powerful solution. Tension’s HPS-300 Variable Length Poly Bagging System reduces reliance on manual labor while increasing productivity, packaging up to 18 items per minute—four to five times faster than manual packing. By automating right-sized packaging for items like clothing, shoes, and soft goods, the HPS-300 helps businesses cut costs, improve efficiency, and stay ahead in a competitive market.

In our previous post, we discussed how our HPS-300 Variable Length Poly Bagging System can help solve a need for sustainable packaging solutions by creating less waste inside and outside of the package. Now, we’ll explore how the HPS-300 can help organizations overcome issues related to labor shortages.  

The “Why” Behind Labor Shortages 

Labor shortages, especially for warehouse workers, were a challenge prior to the Covid-19 pandemic and have since become exacerbated, with more than 19 million US workers having quit their jobs since April 2021.  

Financial incentives in the form of higher hourly rates are simply not working in terms of attracting new, quality and long-term talent. Instead, they attract short-term employees and tend to cause loyal, tenured associates to become disgruntled if they are not also financially rewarded. Secondly, the days of endless labor supplied at low wages are long gone. Associates seek a work/life balance, recognition and rewarding, enjoyable work. This means flexible schedules, time off when needed and reduced physical requirements of the job when possible. 

The answer for improvement in labor shortages and related associate satisfaction lies in automation. Companies can incorporate it to help reduce physical demands, training and overall staffing with their labor force and get packages to customers in a shorter amount of time. 

The Ideal Automation Solution: Tension’s HPS-300 

The HPS-300 variable length poly bagging system creates right-sized packages to reduce packaging waste and uses cost-effective C-Fold poly film material with a heat seal to create a tamper-resistant, durable package.

Designed specifically for shipping variable size items, the HPS accepts a continuous stream of products, determines the optimum size for the length and creates a finished package. It’s an ideal solution for packaging clothing, soft goods, shoes and boxed items. It is also modular in design, which enables us to add different features depending on customers’ needs, such as rate shopping, weight verification and pre-weights.  

The HPS-300 can act as a standalone system and/or be integrated into a current production line. It integrates with transport management (TMS) and warehouse management (WMS) software, and can be easily combined with weighing, print and apply and sorting systems. 

More Packages, Less Labor

The HPS-300 helps our customers to boost productivity with less labor. With capabilities of up to 18 packages per minute, the HPS-300 enables distribution centers to increase throughput versus manual packaging processes.  

Quality-built for long runs, the HPS-300 uses cost-effective material, reduces labor costs (and need), and packages about four to five times faster than manual hand packing.  

Stay Connected with an Industry Leader

Tension Packaging & Automation is a leader in complete packaging and automation solutions for the eCommerce and pharmacy automation industries. Tension designs and builds equipment and systems, in addition to providing the consumables, software, and service and support that help pharmacies and eCommerce fulfillment centers optimize productivity. 

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  • Best practices in packaging and automation 
  • Pharmacy automation systems know-how 
  • eCommerce packaging equipment know-how 
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  • Product spotlights 

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Tension Packaging & Automation is a leader in complete packaging and automation solutions for the eCommerce and pharmacy automation industries. Contact us to get started. 

The Perfect Fit Part 1, Sustainable Packaging Solutions

tensionapdev on June 21, 2022

Sustainability is a growing priority, with 72% of Americans more likely to repurchase from brands that ship sustainably. Tension Packaging & Automation supports this shift with solutions like the HPS-300 Variable Length Poly Bagging System, which creates right-sized packages to reduce material usage and waste. By combining durable consumables with innovative automation, we help businesses protect the environment while optimizing efficiency.

According to a recent study, 72% of Americans would be more likely to purchase again from brands that ship sustainably (i.e., use less plastic). This research resonates with our customers, as many have expressed to us the need for sustainable packaging solutions. 

Tension Packaging & Automation is an organization committed to our environment and our customers. We offer a variety of sustainable packaging solutions (including the means for customers to use less plastic when packaging goods) from equipment to consumables, with precision focus on quality in all we do.  

Improving Sustainability Through an Operational Approach 

Sustainability goes beyond consideration for our environment; it’s taking responsibility for the environment and incorporating sustainability into your operations, processes, and entire approach to business. 

Through our Lean and Continuous Improvement culture, Tension strives to offer the highest quality in everything we do. This translates into durable, quality paper and poly consumable options that better protect the contents inside the package, which eventually reduces landfill waste from damaged items. The same approach to quality holds true for our equipment — and in the case of our HPS-300 variable length poly bagging system, we can create a poly bag that is right-sized for a product, reducing the amount of material needed for the package and ultimately the waste produced.  

Ultimately, by using quality consumable materials yet less of them when we create our packages, we better protect our environment both from potential waste inside the package and from the package itself. 

The HPS-300 Variable Length Poly Bagging System for eCommerce Automation

Our customers expressed a need for an eCommerce packaging solution that accepts a continuous stream of different sized goods while using less material than a fixed-size bag and with a variable cutoff. Packages are right-sized to help reduce packaging waste, and the HPS-300 uses cost-effective C-Fold poly film material with a heat seal to create a tamper-resistant, durable package. 

Designed specifically for shipping variable size items, the HPS accepts a continuous stream of products, determines the optimum size for the length and creates a finished package. It’s an ideal solution for packaging clothing, soft goods, shoes and boxed items. It is also modular in design, which enables us to add different features depending on customers’ needs, such as rate shopping, weight verification and pre-weights. 

Variable length bags created on the HPS-300 save costs on material, resulting in a tighter, smaller package. The easy-to-operate HMI touchscreen control panel enables the system to be operated by a single user. This is a major benefit in our current environment where labor is hard to find (stay tuned for Part 2 of this post to learn how our eCommerce packaging solutions can help organizations navigate labor shortages). 

Stay Connected with an Industry Leader

Tension Packaging & Automation is a leader in complete packaging and automation solutions for the eCommerce and pharmacy automation industries. Tension designs and builds equipment and systems, in addition to providing the consumables, software, service and support that help pharmacies and eCommerce fulfillment centers optimize productivity. 

Contact Tension

Founded in 1886, Tension Corporation – parent company of Tension Packaging & Automation – has a legacy of delivering excellence and innovation for envelope products, packaging and packaging automation solutions.  Contact us to get started on your sustainability journey. 

Product Spotlight: HPS-300

tensionapdev on March 8, 2022

With over 75% of specialty retail supply chain leaders prioritizing 2-day delivery, efficient packaging is essential for meeting customer expectations. Tension’s HPS-300 Variable Length Poly Bagging System is designed to streamline operations by creating right-sized, securely sealed packages for variable-sized items. Capable of producing 8 to 18 packages per minute, it integrates seamlessly with WMS and TMS systems, offering accuracy, cost savings, and adaptability for eCommerce businesses.

A recent survey by McKinsey & Company highlighted that more than 75% of specialty retail supply chain leaders have made 2-day delivery a priority, and 42% are aiming for same-day delivery by 2022.

Subsequently, competitive changes in the retail space have driven customer expectations. Consumers increasingly seek convenience from companies they choose to do business with in the form of expedient deliveries and delivery options, while the companies grapple with how to deliver in this environment in terms of their operational efficiencies.

Retailers who seek efficiencies in their packaging operations can benefit from Tension’s HPS-300 horizontal packaging system.

What is the HPS?

Designed specifically for shipping variable-sized items, the HPS-300 variable length poly bagging packaging system accepts a continuous stream of products, determines the optimum size for the length of the package, applies a shipping label and creates a finished package. It features a built-in print and apply labeling section and next bag out technology, assuring your customer’s packages is accurately bagged, sealed and labeled. In typical operations, the HPS-300 can produce 8 to 18 packages per minute.* And with the strong, cost-effective C-Fold poly film material, the HPS-300 creates a sturdy package that is securely sealed with Tension’s proprietary heat seal technology.

*Actual throughput is dependent upon multiple factors including staffing productivity and performance, workflows, data interfaces and availability of product to the system.

HPS-300 Benefits

In addition to its ability to accept a continuous stream of variable-sized items, the HPS-300 features a variety of
other benefits:

  • Right-sized Packaging: Variable length provides a tighter, smaller package and saves on
    material costs.
  • Accurate Orders: Built in print-n-apply labeling system with Next Bag Out technology.
  • Ease of Operation: HMI touchscreen control panel takes the guesswork out of operation.
  • Adaptable: Integrates with your WMS and TMS software systems.
  • Secure: Heat sealing method creates a sturdy seal for your package.
  • Flexible Package Sizes: Can create packages up to 21.5″ wide x 30″ long with a 7″ pass thru.

Popular Options for the HPS-300

A variety of options are available based on your needs and configurations. Some include:

  • Inline scale
  • Package sorting system for multiple carriers & service levels
  • Belted infeed and exit conveyor
  • Shrink Tunnel
  • Workstations and a Put-to-Pack Wall
  • Middleware software integration with optional productivity reporting

Additionally, a unique sorting system can be added to create your complete package processing system.

Who Needs the HPS-300?

Tension’s HPS-300 is an ideal eCommerce packaging solution for apparel and shoe companies, especially if they need a system to handle a continuous stream of variable sized items. The HPS-300 is also a good solution for companies who package soft goods and boxed items, such as bed linens or other household items.

Watch the HPS-300 Video

Seeing is believing: Watch this video of how our HPS-300 accepts a continuous stream of products, determines the optimum size for the length and creates a finished package.

Want More Information?

Give your eCommerce and fulfillment operations a boost toward more efficiencies in 2022 with an HPS-300 variable
length poly bagging packaging system. Contact us to get started today, or check our product page for more details.

Heat Seal vs. Cold Seal Packaging: Which Option is Right for Your Packages?

tensionapdev on February 8, 2022

With global parcel volumes projected to double by 2025, selecting the right packaging equipment is crucial for handling increased demand. Heat seal packaging offers strong, weather-resistant seals ideal for clothing and soft goods, while cold seal packaging is perfect for dense items like books and electronics, offering cost and productivity benefits. Tension Packaging & Automation provides tailored solutions to optimize your operations and meet your growing needs.

According to a recent study, global parcel delivery volumes will increase by 100% by 2025. In addition to their annual peak season rushes, retailers and order fulfillment companies have a need to prepare for greater package volumes to come over the next few years.

When choosing equipment for your operations – and especially as you plan for growth – understanding the difference between heat seal and cold seal for packages can help guide your overall logistics strategy.

What is Heat Seal Packaging?

As the name implies, heat seal packaging uses heat to melt the sides of film packaging together to create a seal. In packaging applications, a heat seal can be used to both create a bag from two sheets of poly film and/or to secure the bag closed.

Heat Seal Benefits

  • Protective Material: This material provides a strong package that helps to protects contents from harsh weather conditions, such as rain or snow (and the lighter weight material can possibly reduce shipping costs).
  • No Adhesives Required: Because a heat seal uses heat to create the seal, there is no need for special pressure-sensitive adhesives.
  • Increased Productivity: Using one of Tension’s automated heat seal solutions, you can pack and prepare 8-16 packages for shipment per minute, on average, vs. 1.5 packages per minute using a hand packing method. Additionally, the variable length system helps create a right-sized package that could save you on shipping costs.

What is Cold Seal Packaging?

Cold seal packaging refers to water-based adhesives that are used to seal paper (e.g., kraft corrugate) and film packaging material. Cold seal is a self-sealing type of closure, only requiring pressure to create the seal on a package.

Cold Seal Benefits

  • Product Protection: Box-style packages* created from a cold seal eliminate the need for void fill, which creates increased protection for products inside.
  • Increased Productivity: Keep your machine running fast with easy-to-use features like batch processing or length adjustments for variable sized packages with capabilities of up to 8-16 packages for shipment per minute.
  • Cost Controller: Because cold seal packaging equipment requires no heating elements, it reduces costs related to electrical consumption.

Heat Seal vs. Cold Seal: Who Uses It?

A cold seal is ideal for companies packaging harder, dense products, such as books, CDs, DVDs or video games. Conversely, a heat seal is an ideal solution for companies packaging clothing, soft goods, shoes and other boxed items.

Contact Us

All packaging equipment is not created equal: Your products often dictate your seals and other packaging needs. Contact an expert at Tension to learn about solutions that can help optimize your productivity.