Packaging and Shipping Automation: Choose a Partner, Not Just a Vendor

Meagan Young on December 19, 2025

When you’re evaluating fulfillment automation solutions for eCommerce or pharmacy operations, it’s easy to focus on the machinery. Specs, cycle rates, integration points, and price all matter. They just don’t tell the whole story. The vendor behind the system will influence your uptime, your accuracy, and even how confidently your team can push through seasonal, clinical, or regulatory demands. Automation isn’t a one-and-done purchase. It’s a long-term relationship that should strengthen your operation’s daily performance.

Here’s what to look for when choosing a packaging and automation partner—and why those qualities matter.

1. Ongoing Service and Support

When something goes wrong in a fulfillment or pharmacy environment, you don’t have hours to spare. You need quick answers, trained technicians, and a service structure that gets you back online. A strong partner offers responsive troubleshooting, predictable maintenance plans, and technicians who know your system inside and out.

eCommerce Example: Picture your automated bagger stalling on Cyber Monday. Orders keep flowing, but your system isn’t. A partner with fast-response support and stocked replacement parts prevents a three-hour hiccup from becoming a three-day backlog. Their goal should be to treat installation as the starting line, not the finish line.

2. A Comprehensive Offering

Your automation equipment doesn’t operate in a vacuum. You need compatible machines, software, packaging materials, labeling systems, and often robotics or conveyance. A partner with solutions and experience across the full ecosystem can help you avoid patchwork fixes that slow operations or introduce errors.

Pharmacy Example: A central-fill pharmacy may run multiple dispensing technologies while relying on mail-ready packaging downstream. If those pieces come from different vendors that don’t integrate well together, troubleshooting becomes a guessing game. Your equipment provider should be able to design a cohesive workflow that works within your operation.

3. Industry-Specific Expertise

eCommerce and pharmacy operations have very different requirements. Pharmacies must maintain chain-of-custody, patient safety, and compliance. eCommerce teams battle extreme volume swings, SKU variability, and customer expectations for speed. A knowledgeable partner understands these pressures and designs systems around them.

eCommerce Example: A third-party logistics (3PL) provider shipping thousands of SKUs needs packaging flexibility and fast changeovers. If a vendor doesn’t understand that, you end up with bottlenecks every time a client changes their product mix. A partner with direct fulfillment expertise builds solutions that keep your lines moving even when your inventory shifts hour by hour.

4. Lifecycle Management

Automation systems evolve. Parts wear, processes change, and your facility will almost certainly adapt its workflow over time. Lifecycle management includes preventative maintenance, performance tracking, upgrades, and end-of-life planning. You want a partner who supports you long after go-live.

Pharmacy Example: A specialty pharmacy may add new medication programs or increase patient volume. Without lifecycle planning, the original system becomes a limitation. A partner who monitors performance and suggests upgrades keeps your throughput steady and your accuracy intact.

5. Training and Empowerment

A strong automation partner brings a service team that knows the equipment down to the component level. Their technicians should understand system operation, detailed schematics, fault diagnostics, and the full spare parts strategy. That depth of knowledge keeps your operation moving because problems get resolved quickly and accurately.

eCommerce Example: If a conveyor fault stops your packing line during a high-volume afternoon, you need a service tech who can diagnose the issue within minutes, not hours. A partner with a deeply trained field team can pinpoint root causes, implement fixes that stick, and keep your backlog from spiraling. Their expertise becomes an extension of your operation when it matters most.

6. Hardware, Software, and Material Integration

Your system needs to communicate and operate seamlessly. Integrated software ensures orders flow cleanly from your warehouse management system (WMS), dispensing, or pharmacy systems to packaging. Materials must feed correctly and seal consistently. A provider who understands all three reduces risk and simplifies your operation.

Pharmacy Example: If your mail pharm system prints patient documentation that doesn’t sync with packaging, you risk mis-picks or delays. A partner who integrates data, labeling, and packaging ensures every order moves through the workflow with minimal touches and maximum accuracy.

7. Scalable, Customizable Solutions

Your needs will change. You may add shifts, expand SKUs, shift packaging formats, or retrofit around legacy equipment. A strong partner offers flexible systems that grow with you, whether you’re reconfiguring a single line or scaling to a second facility.

eCommerce Example: A growing retailer may start with one automated bagger, then expand to multiple workcells as volume increases. A partner who designs for modular expansion prevents you from replacing equipment prematurely. They plan for your next three years, not just your first three months.

The Bottom Line

Choosing a packaging and automation provider is a strategic decision. Beyond a basic machinery investment, you’re investing in expertise, support, adaptability, and a relationship that will influence your daily operational performance. The right partner stands beside you through challenges, growth, and continuous improvement.

About Tension Packaging and Automation

Tension Packaging & Automation brings more than 135 years of experience and a service-first mindset to the pharmacy and eCommerce sectors. Here’s how Tension aligns with the qualities above:

  • Service-First Approach: Tension provides responsive technical support, trained field technicians, and maintenance programs that prioritize uptime and operational continuity.
  • Holistic-Focused Solutions: Tension’s portfolio includes automation equipment, software, packaging materials, labeling, and integrated workflow design, ensuring every component works together.
  • Specialized Expertise: Tension understands pharmacy regulations, fulfillment pressures, and the realities of distribution environments. Their solutions reflect real operational needs, not generic assumptions.
  • Trained Sales and Support Teams: Tension trains its teams on system operation, troubleshooting, schematics, and spare parts planning. They help customers stay confident and self-sufficient.
  • Scalable, Customized Workflow Solutions: Tension excels in deploying flexible systems—new builds, retrofits, and integrated hardware/software/material workflows that evolve with your business.

If you’re ready to explore what a true partnership can look like, connect with Tension’s automation experts today.

Let’s start a conversation.

Driving Innovation in Automation: The Tension Packaging & Automation Advantage

kloggia on December 3, 2024

Leading the Way in Automation Innovation for Unmatched Performance 

In the fast-paced and steady growth industries of pharmacy and eCommerce order fulfillment, the need for advanced automation is growing. At Tension Packaging & Automation, we’ve dedicated over 25 years to designing and delivering scalable, intelligent automation systems. 

Our guiding philosophy—Innovate. Automate. Outperform.—reflects our commitment to building solutions that exceed the demands of our customers. 

Built on a Legacy of Excellence 

With roots in manufacturing and engineering dating back to 1886, our parent company, Tension Corporation, has long been synonymous with innovation and precision. Today, Tension Packaging & Automation continues that legacy as a trusted leader in custom and standard automation solutions tailored to the unique needs of the pharmacy and eCommerce industries. 

From system integration and software engineering to equipment manufacturing, we offer a full spectrum of capabilities to address fulfillment challenges. 

Innovation That Drives Results 

Our automation systems are built with one goal in mind: to empower our customers with unmatched efficiencies and cost savings. Whether it’s reducing manual labor, minimizing DIM surcharges, or ensuring seamless system integration, our solutions can offer measurable ROI. 

Take, for instance, our fitPACK500TM—a versatile, right-sized packaging solution that minimizes end user waste, optimizes package length, width and height dimensions, and reduces shipping costs. This innovation represents just one example of how we combine innovative technology with customer-centric design to solve complex challenges. 

Tailored Solutions for Maximum Impact 

At Tension, we know there’s no one-size-fits-all approach to automation. That’s why we work closely with our clients to design and implement systems that align with their operational goals. Our solutions span: 

  • eCommerce Automation: Systems such as our Scan Label Apply Manifest (SLAM) Line simplify order fulfillment with automated package identification, labeling, and sortation and manifesting. 
  • Integration Software: Our proprietary TensionCONNECTTM ensures flawless communication between hardware and software components, and powers the technology in our solutions. 

Unmatched Support and Expertise 

Automation isn’t just about the machines; it’s about the people behind them. At Tension Packaging & Automation, our skilled engineers and field service technicians are dedicated to your long-term success. From initial installation to ongoing maintenance, we’re with you every step of the way. 

Experience Tension at ProMat 2025 

Want to see our innovations in action? Join us at ProMat 2025, where we’ll showcase solutions like the fitPACK500TM and demonstrate how our automation systems can transform your operations. 

A Future of Endless Possibilities 

As industries evolve, so does Tension Packaging & Automation. Our forward-thinking approach ensures that we’re always one step ahead, developing technologies and partnerships to tackle the challenges of tomorrow. With Tension, you can trust that you’re not just adopting automation—you’re investing in a future of unmatched performance and efficiency. Ready to innovate, automate, and outperform? Explore our solutions at tensionautomation.com or contact a sales expert today. 

 

Sustainable Packaging Part 2: Right-Size Packaging

tensionapdev on October 16, 2024

Right-size packaging minimizes waste by tailoring each package to its contents, reducing costs, DIM weight charges, and environmental impact.

Sustainability is reshaping the packaging industry, and automation is key to scaling up without sacrificing efficiency. In this second part of our series on sustainable packaging, we explore right-size packaging—a critical component for businesses striving to meet both operational and environmental goals. 

What is Right-Size Packaging? 

Right-size packaging uses technology to tailor each package to the exact size of its contents, minimizing waste. When a right-sized package is created, it’s optimized to fit the contents as closely as possible, minimizing excess material and wasted space. Smaller, right-sized packages mean lower shipping and dimensional (DIM) weight charges. When shipping a right-sized package, as volume increases so do the savings. 

The new fitPACK500™ from Tension leads the charge in right-size packaging technology, offering a scalable solution that adjusts package length, width, and height automatically. With the ability to create 10-20 packages per minute, it delivers not only sustainability but also speed and cost savings. 

Sustainability Benefits of Right-Size Packaging Systems: 

Right-sizing packaging systems can reduce shipping costs through design efficiencies, but this technology can also decrease environmental impacts in a way that carries sustainability benefits throughout the supply chain: 

  • More Truck Space: fitPACK500 creates packages, deflates air, and labels them in one seamless operation—without sacrificing speed. Less space is needed to transport the smaller, more compact packages created with the right-size packaging technology, allowing a larger number of packages to be loaded on a truck for shipment. 
  • Lower Emissions: Because right-size packaging technology allows for a larger number of packages to be included on a truck for shipment, less fuel is needed and eventually this means fewer vehicles on the road. 
  • Sustainable Returns: Customers appreciate receiving packages that are appropriate in size and not overfilled with fillers or empty space. Plus, right-size packaging with included adhesive strips that convert the package into a return package can further help reduce emissions as more space is provided for other return packages in the truck.

Who Needs Right-Size Packaging Systems? 

eCommerce businesses in sectors like fashion, electronics, and home goods can all benefit from right-size packaging. In states like New Jersey, where legislation may soon require better-sized packaging, these systems provide an immediate solution. They’re particularly valuable for businesses shipping a wide variety of item sizes, such as 3PL and drop shippers, helping to reduce both costs and waste. 

Let’s Talk Packaging 

Sustainable, efficient, and cost-effective—right-size packaging is the future of order fulfillment. Explore the benefits of fitPACK500™ by contacting a Tension expert today to request a personalized demo. 

Sustainable Packaging Part 1: Polybags with Recycled Content

tensionapdev on September 18, 2024

Tension’s polybags with recycled content offer a sustainable packaging solution that combines product protection, custom branding, and eco-friendly compliance, helping businesses meet evolving environmental regulations while reducing their impact.

Sustainable packaging is no longer just a trend—it’s becoming law across the U.S. States like Maine, Oregon, New Jersey, Minnesota, Washington, California, and Colorado have enacted Extended Producer Responsibility (EPR) laws, pushing businesses to adopt sustainable practices. More states are considering similar measures, and packaging is at the forefront of this shift. 

Your shipping packages play a critical role in not only delivering products safely but also maintaining your brand’s promise. Now, with sustainability taking center stage, these packages must also comply with environmental regulations. That’s where we come in. Tension’s polybags made with recycled content offer a sustainable packaging solution that aligns with your environmental goals. 

What is a Polybag Made with Recycled Content? 

At Tension, we offer L-LDPE polyethylene films containing post-consumer recycled (PCR) and post-industrial content (PIC). These polybags are a win-win for both product protection and environmental responsibility, offering up to 80% PCR content or more depending on testing. This percentage is a powerful marketing tool for brands committed to sustainability. Pair it with our fitPACK500TM system to create right-sized packaging that further reduces environmental impact through the use of less packaging material, which offers benefits throughout the supply chain. Stay tuned for Part 2 of this post to learn more about the sustainability-related benefits of fitPACK500.

Key Benefits of Polybags with Recycled Content: 

  • Custom Branding: Make a statement with logos and sustainability messages directly on the packaging. Highlight your eco-conscious efforts for customers who care. 
  • Recyclability: These polybags are recyclable at #4 plastic recycling locations, such as retail and grocery stores. 
  • Durability: Made with strong polyethylene materials, these polybags withstand the rigors of shipping, keeping products safe. 
  • Tested for Your System: Our packaging is rigorously tested to ensure compatibility with your machinery, minimizing wear and tear. 

Who Needs Polybags Made with Recycled Content? 

These polybags are ideal for businesses across a variety of industries, from fashion apparel, toys, sporting goods, jewelry, health and beauty items, home improvement, computer accessories, small electronics, home furnishings and more. For businesses looking to balance product protection with sustainability, Tension’s packaging solutions are the answer. 

Ready to Make the Switch? 

If you’re aiming to meet both branding and sustainability goals, our experts are ready to help. Contact Tension today to discuss the best polybag solutions for your unique needs. 

Three Ways to Incorporate Sustainability into Packaging Operations

tensionapdev on August 19, 2024

Incorporating sustainability into packaging operations can be achieved through the “Reduce, Reuse, Recycle” approach: reduce waste with right-sized packaging, design reusable packaging for returns, and prioritize recyclable materials—all contributing to a greener, more efficient supply chain and meeting growing demands for eco-friendly business practices.

Environmental concerns are at the forefront of consumer and corporate priorities. This is especially true in packaging and related industries: Businesses are increasingly looking for ways to make their operations more sustainable. Packaging, a critical component of product delivery, often contributes significantly to waste and environmental impact and companies are seeking to transform their operations to be more eco-friendly. 

Let’s explore three effective strategies for sustainable packaging with the help from a common slogan: Reduce, Reuse, Recycle. Reducing packaging through right-sized designs, reusing packaging for product returns, and recycling materials like paper and plastic. These steps not only benefit the environment but also enhance operational efficiency and meet the growing demand for sustainable business practices. 

Reduce: Create Right-Sized Packaging Tailored to the Product 

One of the most effective ways to incorporate sustainability into packaging operations is by reducing the amount of packaging used. This can be achieved by creating right-sized packaging tailored to the specific dimensions and protection needs of the product through solutions such as the fitPACK500TM. Right-sized packaging not only minimizes material use but also reduces the overall volume and weight, leading to lower transportation emissions and costs. This is especially relevant for packaging supplies for clothing, as consumers often order multiple sizes of a garment in pursuit of the best fit. By optimizing the size and materials of the packaging, businesses can significantly cut down on waste and contribute to a more sustainable supply chain. 

Reuse: Design Automated Packaging Equipment for Return Packaging 

Reusing packaging is another crucial aspect of sustainable packaging operations. One practical approach is to design automated packaging equipment for product returns. By including a mechanism to create a return strip on the package, it enables the package to function as a two-way for product returns if needed. This not only extends the life cycle of the packaging but also provides customers with a convenient and eco-friendly way to return items. For instance, durable packaging materials and easy-to-reseal designs can encourage customers to reuse packaging rather than discarding it after a single use. Implementing a returnable packaging system can significantly reduce waste and promote a circular economy. 

Recycle: How to Recycle Paper and Plastic Packaging

Recycling is an essential component of sustainable packaging operations. Businesses can prioritize the use of recyclable materials such as paper and plastic in their packaging designs. Encouraging customers to recycle packaging by providing clear instructions and information about recycling facilities can further enhance the effectiveness of this approach. Additionally, using recycled content in new packaging can help close the loop, reducing the demand for virgin materials and decreasing the overall environmental footprint. By integrating recycling practices into packaging operations, companies can contribute to reducing waste and conserving natural resources. 

Contact Tension Packaging & Automation 

Incorporating the reduce, reuse, and recycle concept into packaging operations can significantly enhance sustainability efforts for your company. By optimizing packaging design, encouraging reuse, and prioritizing recyclable materials, businesses can play a crucial role in promoting environmental responsibility and achieving long-term sustainability goals. Contact the experts at Tension to explore our sustainable packaging options today. 

Getting Started with Automation: A Guide for Your Warehouse Management Solutions | Part 5, Service and Support Considerations, Installation

tensionapdev on July 26, 2024

Effective automation implementation requires comprehensive planning and support, and Tension Packaging & Automation ensures seamless transitions with expert equipment installation, robust service plans, and tailored training programs, empowering your warehouse to scale smoothly and achieve long-term operational success.

Your company has completed all the planning to analyze what automation equipment your fulfillment processes need to eliminate bottlenecks and provide a pathway to sustainable growth. Congratulations! You may correctly feel that the light at the end of the tunnel is in view. But if you’re also feeling apprehension, you’re not wrong there, either. Effective implementation is the crucial final step that helps determine whether a steep learning curve and/or service issues turn what should be a solution into a new problem. After all, buying your equipment is really only the start of your automation journey.  

How do you ensure that you’re prepared to move forward and get the most out of your new equipment? Here are the considerations that can help your plans to go live unfold as smoothly as possible. 

How Do You Go Live? 

With any new equipment or change in processes, you’ll need to be prepared for an adjustment period as your employees become familiar with new machines and how they fit into (or transform) previous ways of doing things. This is one of the reasons we recommend starting small if your company hasn’t previously done integrations or used automation equipment before. You can keep familiar processes that work and gear your automation selections toward improving what isn’t as effective, easing staff transition into new ways of doing things. Tension Packaging & Automation helps our clients create optimal go-live plans that minimize disruptions and give you a clear roadmap for getting your new systems up and running. 

What are critical questions you need the answers to when creating these plans? First, who is going to do the install? The answer will vary depending on the type and complexity of the equipment. Next, who is going to train the staff? Keep in mind that staff training is never a one-and-done proposition. You may have an outside company come in and train all the employees who will be working with new equipment when it is first installed, but what happens months or years down the road when there are new hires, or there are internal moves that pair someone with machines they haven’t worked with before?  

Factory Trained Expertise 

At Tension, we set you up for long-term knowledge and success through our team of factory trained implementation managers and service technicians who will install your newly purchased equipment. Your equipment will be placed, powered, set up, and site acceptance tested per agreement guidelines. Extensive operator training and train the trainer programs are available, and Tension is available for additional training support should you need a refresher due to seasonal work or unexpected turnover.  

Will your company have someone in the building to support the equipment? While Tension designs our equipment for rugged reliability, machines that are in constant use may require service outside of its planned maintenance. The majority of equipment concerns can be resolved over the phone. If a site visit is required, we can quickly dispatch technicians quickly to resolve issues and get the equipment operational again.  Will you have an inside mechanic available for ongoing maintenance and troubleshooting? We also provide training for in-house technicians to ensure they can work on your equipment with confidence. 

Automation Equipment Solutions Service Plans 

Service and support are a natural part of working with automation equipment. The type and level of support your company will need is as custom as the automation solution that is right for your situation. Tension has a variety of customer service plans and service agreements that enable you to choose the level of support that fits your organization’s needs. Our nationwide support staff ensures that there is always someone on call. Additionally, service and support plans offer a variety of benefits to include priority phone service, priority site visits, discounted labor rates and discounted preventative maintenance programs. 

Spare Me 

Finally, what parts will you need to keep equipment running smoothly in the warehouse? The right spare parts kit will depend on your specific system. Tension will provide a list of recommended spare parts to keep the equipment running optimally and reduce downtime so that routine fixes will not bring your fulfillment processes to a halt while you wait for parts to arrive. 

Your Automation Partner Today and Into the Future 

If your company is one of the many with little (or no) existing automation in your fulfillment processes, Tension Packaging & Automation can provide the guidance and support you need to not only take your first steps but also to create a system that can grow with you. We’re the partner you can rely on every step of the way. To learn more about how we can help you modernize your eCommerce or pharmacy fulfillment, contact us here today.

Getting Started with Automation: A Guide for Your Warehouse Management Solutions | Part 4, Equipment Recommendations: What Is the Best Option?

tensionapdev on June 25, 2024

Choosing the best automation equipment for your warehouse depends on unique operational needs, and thoughtful selection should align with integration, employee buy-in, and technical requirements—ensuring smooth, efficient, and impactful fulfillment processes tailored to your business.

If you’ve read our previous installments in this series, then you can probably already anticipate the short answer to the question “What is my best option for automation equipment?”: 

“It depends.”  

While eCommerce and pharmacy fulfillment companies may share similarities in the challenges they face, once a business has reviewed its current operations, crunched the numbers, and analyzed its order flow, it will be obvious that to be effective, the selection of automation equipment is not a one-size-fits-all solution.  

By the time a company has put together the information from Parts 1 through 3, they should have a clearer idea of what kinds of equipment will yield the biggest positive impact on optimizing order fulfillment. Next we’ll talk about buy-in and additional considerations to take into account when making decisions on which kinds of equipment to purchase. 

Getting Buy-In on Equipment 

Ideally, the workers who form the backbone of a company’s existing fulfillment processes have been a valuable source of information on what has been working and what can use improvement during the research stages of this journey. It’s essential to note that while automation drastically reduces the amount of manual labor needed for order fulfillment—particularly repetitive tasks that can result in injuries and errors—there are no human-free systems. Skilled, knowledgeable employees will always be needed to keep orders flowing and to deal with any anomalies that require intervention.  

The key is that thoughtfully chosen automation allows your workforce to be more productive in a safer, less stressful environment. The recommendations arrived at from the first three steps will naturally be different for each company. However, the right solution for your company should have immediate benefits that are obvious to your employees, whether that is an automated packer that eliminates hand packing or a tabletop bagging machine that opens the bag, labels it, and seals it after contents have been loaded. If you’re using cartons, equipment that automates weighing, void fill, and packing slip insertion speeds throughput while reducing errors. When rate shopping is a goal (or an existing bottleneck) a SLAM (scan-label-apply-manifest) system can take the headache out of minimizing shipping costs. Finally, automated sortation makes it possible to sort packages of different weights, shapes, and sizes quickly and accurately in a smaller space footprint to go to multiple carriers at multiple service levels. When employees understand the rationale and receive the training and support to ensure that the new systems work as intended (more on that coming in Part 5!), then your company will be able to get the most out of their investment in automation. 

Integrations 

Another essential question a company introducing automation technology should be asking at this point is what they are doing for integrations. First, the hardware and machinery chosen will need to operate smoothly with the software in use. This includes your warehouse management system (WMS), which controls operations from when goods enter your warehouse until they move out, and transportation management systems (TMS), shipping software that helps optimize shipping costs and efficiency.  

In addition, before anything is moved in the door, equipment integration must be planned for. How will new technology flow in the warehouse with current processes? And where will new equipment be placed? The application engineer on the project should provide drawings showing the proposed layout making it clear exactly how the process incorporating the new automation will be situated and function. 

Tech Requirements 

The last step before your company is ready to move ahead is to ensure that all the technical requirements for your selected equipment can be met. Depending on the machinery chosen, power requirements can vary, and pneumatic features may have air needs that also need to be considered. For example, a tabletop bagger may only need a standard outlet, while larger equipment may need higher voltage and amperage. The layout should be reviewed to ensure that such requirements can be met in the proper locations, and if upgrades are needed, they are planned and budgeted for. 

In addition, data needs should be taken into account for printing addresses on polybags. What printer language will the system be using—e.g., Zebra, Datamax, or SATO—and will you be set up to ensure that your equipment can communicate seamlessly? 

Your Partner in Strategic Automation 

Even when you know the right questions to ask and are sure automation is the logical next move for your fulfillment operations, making the leap can feel like daunting. The team at Tension Packaging & Automation is here to give you the expert support you need to chart the best path forward for your company and move ahead with confidence. To learn more, contact us here today.  

Getting Started with Automation: A Guide for Your Warehouse Management Solutions | Part 3, Order Flow from Pick to Ship

tensionapdev on May 24, 2024

Optimizing your warehouse’s order flow from pick to ship is critical for effective automation, and Tension Packaging & Automation helps identify and streamline processes—from order picking and packing to carrier rate shopping—reducing costs and boosting accuracy, all while supporting your business’s growth and efficiency goals.

 In the first two parts of this series, we laid out preliminary steps that set the stage for making strategic choices on how best to incorporate automation into order fulfillment to increase accurate throughput, reduce labor costs, and position businesses to accommodate continued growth. First, we went through questions a business should be asking itself about its current operations when it has become apparent that manual processes aren’t keeping up with demand. Then we moved on to looking at numbers—the budget they’re able to invest in automation solutions, their current labor costs (factoring in overtime and expenses for temporary hires), and the expected time frame to realize a full return on investment.  

The next step is to take a closer look at order flow—the steps necessary to select inventory to fulfill an order and prepare it to be handed off to the selected carrier. Order picking and packing methods vary, and understanding how your system works now and where improvements are possible is an essential part of selecting the right equipment to create a truly effective automation solution. 

Breaking Down Your Order Flow 

Order picking is the first part of the process to look at. In general, the internal goals for this step are to optimize the process by minimizing the distance workers have to travel, maximizing the use of the space you have available, minimizing picking errors to reduce returns, and minimizing on-the-job injuries. If your existing processes do a good job of this, then steps toward automation should be taken with an eye to integrating with what’s already working. If not, then incorporating automation can be an opportunity to rethink how orders are handled to make needed improvements. 

Start with these questions: How does an order get picked? Do you use a cart system, with operators going to where goods are located to select what’s needed? Or do you use conveyor delivery? Or carton delivery? Once an order has been picked, how does that order get to the pack station? And what does the packer’s job entail to get that order safely packed and ready to ship? 

Another important question to ask is do you rate shop for various shipping carriers? If the answer is no, then ask yourself: Do you need to? And do you want to? It is entirely possible that your business determined that one carrier offers the best rates for your requirements, and taking time to rate shop isn’t necessary to keep shipping costs down. Or you may simply not have rate shopped before because trying to do it manually, package by package, wasn’t practical. Automated rate shopping can help reduce shipping costs without adding a labor-intensive step to the process.  

A related question is how are you capturing DIMs (dimensional weights)? Carriers will charge more for a package with a DIM weight higher than its actual weight, because it isn’t in their best interest to take up cargo space with low-cost large, light packages. Identifying the correct dimensions is important for accurate manifesting as well as for rate shopping, and it represents another area where automation can produce savings without burdening workers. 

Packing can also benefit from solutions that improve throughput and free up valuable employee time from low-level, repetitive tasks. Right now, how many orders is a packer shipping out in a day? How is labeling done? And how is each package sorted to be delivered to the carrier? Each of these steps is another opportunity to strategically automate. 

Finally, how many shipping carriers do you typically use? Do you always work exclusively with major carriers, or do you supplement with gig carriers during peak shipping times? The answers to these kinds of questions will help determine what equipment is necessary to support your requirements now while also giving your business room to grow and improve. 

Expert Guidance in Your Automation Journey 

If your eCommerce or pharmacy fulfillment company is just beginning to make a move into automation, you may not know what is possible, let alone the best strategy for optimizing your processes. Don’t worry—the team at Tension Packaging & Automation is here to walk you through your options, analyze your requirements to create a personalized solution, and provide the support you need to get the most out of your investment. To learn more, contact us here today. 

Getting Started with Automation: A Guide for Your Warehouse Management Solutions | Part 2, Aligning Productivity Goals with ROI

tensionapdev on April 16, 2024

Aligning automation investments with productivity goals involves evaluating your budget, calculating ROI by analyzing labor costs and operational efficiencies, and strategically planning for scalable solutions—ensuring your fulfillment processes grow smoothly and cost-effectively with your business.

In Part 1 of this series, we looked at the first step a business should take when it has become apparent that relying on manual labor alone isn’t enough to meet their fulfillment demands—taking stock of their current business operations. Getting a general overview of the extent to which you’re relying on extraordinary efforts to keep up with surges (or even ordinary demand), assessing the specifics of how much and what you’re shipping, and mapping out your growth goals helps to illuminate where your bottlenecks are and the types of equipment that would not just alleviate them but also expand your capacity. 

The next step is to talk budget. No business has unlimited resources to immediately implement every automation solution that might benefit their situation all at once. Nor is that necessary. Having a firm handle on your numbers will help guide decisions for which equipment will provide the biggest bang for your buck as you create a system that can be adapted and grow with your company. 

Budget and Return on Investment 

The obvious first question is what is your budget? This doesn’t have to be an exact figure, but rather a range that represents what is available to start your operation’s move into automation. It’s possible that you will be able to make a solid beginning without having to use all your allocated resources at the outset, or you may decide, once you’ve looked at the big picture, that it is worth investing a little more. Having a range in mind, however, will ensure that your plans are focused on what is realistic. 

A big part of taking the leap into automation hinges on the question—will it be worth it? Or more accurately, when will it be worth it? To answer that, you’ll need to discuss your expected return on investment (ROI). An effective automation solution for distribution and fulfillment is designed to lower costs by significantly reducing the amount of labor required for daily operations and by lowering (if not eliminating) the need to rely on overtime or additional temporary hires to cope with surges in demand. That means much of the calculation of ROI will be looking at your current labor costs. 

How many packers are you currently paying? How much are they getting paid? Calculate a weighted value that accounts for both the regular hour rate you are paying and overtime, because if you’re regularly relying on overtime using the regular rate alone will not provide an accurate picture of anticipated labor costs without automation. 

Another consideration for ROI is what kind of packing slip you’re using, as it makes a difference for printing out from a networked warehouse management system (WMS). An 8.5 x 11” label takes 8 to 10 seconds per pack, while a Zebra 4 x 6” label takes 2 seconds per pack. This difference can have a significant impact on anticipated throughput. 

To what extent has your business relied on temporary hires? Have they routinely been used to help cope with peaks in demand? The savings realized by eliminating the need for temps can shorten the ROI for automation. Similarly, are you relying on one shift to meet demand, or has your operation required two to keep up? Will automation allow you to eliminate that additional shift? 

Finally, what is your expected time frame to meet ROI on your automation investment? A realistic length of time, back when automation came at a steeper up-front cost and systems were not designed to be readily flexible and scalable, could be around 60 months. Nowadays, 24 to 36 months is more reasonable—or even less. Factoring your goal in will help to inform your automation choices. 

Answering Your Automation Questions 

When your business is poised to move into automation, the fear of making the wrong move can hold you back. Tension Packing & Automation is skilled at helping those just taking their first steps into automation ask the right questions and put together the right information to create the right solutions for eCommerce or pharmacy fulfillment operations. We’ll help you get value out of your automation investment faster. To learn more, contact us here today. 

Product Spotlight: fitPACK500™ Right-Sized Packaging System

tensionapdev on March 7, 2024

With its variable length, width and height capabilities, the fitPACK500TM is a right-sized packaging system that creates packages based on product dimensions, yielding shipping cost savings without compromising throughput.​

Growth in direct-to-consumer (DTC) business and labor shortages have led to increased investments in warehouse and packaging automation. Distribution operations are faced with needs for more throughput, cost performance in automated packaging equipment and sustainable solutions – all demands in addition to a changing warehouse model from eCommerce to a hybrid of eCommerce and retail fulfillment where split-case fulfillment and smaller pack sizes are needed to satisfy the new business model for warehouses. 

Our product innovation team is equally aware of the growth and changing needs in order fulfillment and have come up with the perfect solution in our new, innovative fitPACK500TM Right-sized packaging system. 

What is the fitPACK500 Right-sized Packaging System?

Designed by Tension Packaging & Automation, the fitPACK500 is a “right-sized” order fulfillment packaging system. It is designed for efficiency, reduces waste and creates cost savings. Tailored for variable sized items with capabilities to adjust package length, width and height for each product, it packages without compromising speed. Because the fitPACK500 can create a package according to size, it yields smaller, tighter, right-sized packages that lead to lower shipping costs.   

fitPACK500 Right-sized Packaging System Benefits

Through its innovative design, fitPACK500 offers warehouse distribution operations the ability to create packages according to the product size. This allows distribution centers to process orders with multiple products in varying sizes with right-sized packages, yielding reduced shipping costs and without compromising throughput. 

  • Productivity – fitPACK500 is custom-designed to create a right-sized package without compromising throughput.
  • Reduced Package Waste – Because fitPACK500 creates each package according to product size, package recipients receive packages with reduced package waste. A waste collection bin collects any excess width trim material.
  • Lower Shipping Costs – Because many carriers assign shipping costs according to package size, having the right package size helps get the correct shipping rate and can lead to significant savings on shipping costs over time.
  • Product Protection – Packages are custom-made to fit each product or grouping, creating secure, tight packages to protect the contents better.
  • Intuitive HMI – fitPACK500 is powered by Tension’s proprietary TensionCONNECTTM software that integrates any 3rd party systems. Its smart features include an intuitive user interface that reduces operator training time.
  • High Versatility – fitPACK500 can run different product sizes that call for different film widths through an intelligent 3D scanner. Its unique design allows operators to feed products without batching products or performing manual film changeovers.
  • Modern Modularity – fitPACK500 has enhanced options for further improving productivity. Available upgrades include complete packaging tracking capabilities and an option for “two-way” packaging with a perforation and adhesive strip for package returns.

Who Needs fitPACK500 Right-sized Packaging System?

Tension’s fitPACK500 Right-sized Packaging System is ideal for direct-to-consumer (DTC), business-to-business (B2B) or third-party logistics (3PL) order fulfillment operations who need automated packaging solutions. 

And as a full solutions provider, we offer integration solutions for any existing hardware or software solution in your facility. We also offer comprehensive service and support plans to lend our partners peace of mind in their dynamic and sometimes demanding warehouse environments.

Take a Tour of the Interactive fitPACK500 Product Video

With capabilities to adjust package length, width, and height, the fitPACK500 can create a package according to product dimensions, yielding smaller, right-sized packages that lead to lower shipping costs. Please tour fitPACK500 through our interactive video experience and learn why fitPACK500 is the perfect fit for your order fulfillment. Request your demo of this revolutionary right-sized packaging system here.

Contact Us

Give your order fulfillments operations the perfect fit for growth with Tension’s new, innovative fitPACK500 Right-sized Packaging System. Contact us to get started today or check our product page for more details.