Driving Innovation in Automation: The Tension Packaging & Automation Advantage

emoloney 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 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. 

Warehouse Distribution Solutions Series Part 1: Thriving (not Surviving) Peak with Sortation Equipment

tensionapdev on February 13, 2024

Tension’s Z-Sort sortation system, driven by TensionCONNECTTM software, optimizes peak-season warehouse operations by efficiently and accurately sorting packages of all sizes, reducing labor demands, minimizing downtime, and enhancing productivity—ensuring seamless, scalable solutions for eCommerce businesses.

In this series, our primary focus is discovering innovative solutions that can significantly benefit your order fulfillment business, especially during peak seasons, while ensuring long-term success. And we look for ones that can do so in a way that offers more value for your bottom line with less labor, less downtime and even fewer headaches. We’re thrilled to bring you a captivating lineup of interviews and a range of engaging topics poised to be both insightful and practical. 

Specifically, eCommerce businesses often experience a surge in demand during peak seasons such as holidays, special occasions and  promotional events. These high-demand periods can lead to challenges like labor demands and shipping logistics. This series will explore how Tension’s innovative solutions can seamlessly help you navigate these challenges.

First, let’s look at sortation solutions for effective warehouse management and how Tension’s Z-Sort sortation system can boost operations. 

Sortation Machines for Warehouse Distribution Management 

Z-Sort Sortation, along with TensionCONNECTTM software, ensures packages reach their destinations accurately and efficiently. Our equipment is compact and adjustable, and can fit into small or large warehouse spaces. Its patent-pending, innovative “Z” design can be configured to the number of sortation modules right for your operations and can sort packages of nearly all sizes, shapes, and weights. 

Tension’s Z-Sort allows you to optimize the last step of your order fulfillment process when integrated into your operation by providing increased package sorting rates and improved accuracy with the barcode-driven verification system for carrier selection and class of service. This optimizes staffing requirements by automating hand-sorting operations and reduces floor space requirements. Our sophisticated, flexible design, tailor-made for warehouses, can sort anything from a small package containing lightweight cosmetics to a larger carton. 

The Importance of Software Integrations for Sorting Machines 

It is important to have software to streamline the integration of sorting machines with other equipment. Why? Sortation processes run on our proprietary TensionConnect software, allowing for ease of use, integration, and reporting. It is intuitive and adaptable and built specifically for any operational needs. It ensures all processes and solutions successfully integrate with new or existing equipment and existing software applications. 

Keep in touch with Tension Packaging & Automation for future installments of our Warehouse Distribution Solutions video podcast (vodcast) series by signing up for our eNewsletter here. You can also watch the full vodcast on our sortation solutions below.  

Contact the Experts at Tension for Sortation Solutions 

For more information, contact our team of experts for further details and information. 

Getting Started with Automation: A Guide for Your Warehouse Management Solutions | Part 1, Business Assessment of Current Operation

tensionapdev on February 8, 2024

Assessing your current warehouse operations is the first step toward effective automation; by understanding demand, capacity, and growth goals, businesses can identify where automation solutions, like those offered by Tension Packaging & Automation, can alleviate bottlenecks, reduce overtime costs, and position fulfillment processes for scalable growth.

 

For all the buzz around automation in fulfillment and distribution operations, the casual observer who hasn’t automated their warehouse yet could be forgiven for thinking they’re the last ones to take the plunge. In reality, as recently as 2021 more than 80 percent of warehouses had no automation whatsoever. In some cases, that may be because those businesses took a close look at what they required to meet demand and concluded that they didn’t need automation. But it’s far more likely that they are part of the much larger group that isn’t sure what automation can achieve for them and, more importantly, isn’t sure how to get started implementing a warehouse management solution that would be right for them.

Growth is often the catalyst that pushes a business to move from curiosity regarding automation to an urgent need to do something to alleviate bottlenecks in their fulfillment processes. However, the wrong solution could potentially cost your business money without producing any significant benefit in accurate throughput. In this series, we’ll go through the steps to getting started on your automation journey to help ensure that your chosen solution meets your needs today and into the future. It begins with understanding what’s happening in your business now.

Taking a General Overview

Before you even begin looking at possible equipment and software, the first question is: How is your operation running today? Do you have enough people to keep things moving? Are you getting your orders out on time consistently? And if the answer to that last question is yes, are you using overtime to do so?

If you’re finding your existing workforce can’t keep up with demand on a regular basis, that’s an obvious problem that flags the need to consider automation. However, if you’re relying on overtime regularly to keep up, or surges in order volume routinely overwhelm your company’s ability to maintain timely shipments, these are also signs that your capacity is stretched to a point that limits your potential for growth. Leaning too hard on overtime also erodes your bottom line and runs the risk of burning out your workforce. In these cases, by expanding your capacity, automation helps to keep overtime expenses down and to reduce turnover.

Drilling Down on Specifics

Automation is a general term for different types of equipment, plus warehouse management software, that increase the volume of packages a fulfillment operation can process while optimizing accuracy. What configuration of packaging equipment, conveyor systems, and sortation systems will produce the greatest benefit for a company, however, depends on the specifics of how much and what they are shipping.

Volume is the first consideration. How many orders do you have going out per day? In our experience, around 500 to 1,000 orders a day is a point at which a warehouse should really be looking at options for integrating automation—but that’s a minimum, not a maximum. For a SLAM (Scan-Label-Apply-Manifest) system, it depends on the operation, but 500 orders per day is a general minimum where it starts to make sense.

Beyond that, it also matters what you are shipping and how. Are your products going out in boxes? Bags? What is the average mix per day? For example, if you’re shipping 500 packages per day, is it 200 boxes and 300 bags? This will help determine what type of conveyor and sortation systems would be best, as well as what type of automated packaging equipment might benefit your operation.

How Fast Do You Want to Grow?

The final factor you should be considering at this stage are the growth goals you have for your business in the near future. What are your growth plans in the next two to five years? What percentage of growth are you anticipating or aiming for per year? Twenty percent? Thirty percent?

You don’t have to invest in equipment that can instantly handle the volume your loftiest goals would demand, but you need to be sure your initial configuration is set up to give your operation room for immediate growth targets. You also want to be sure that your system can be readily adapted and augmented to keep pace with increased shipping volume and changing needs. The right solutions will make it easier to expand with a minimum of growing pains.

Your Automation Partner

If it’s time (or past time) for your warehouse to take a serious look at automation, Tension Packaging & Automation is your ideal partner. Our experience in taking eCommerce and pharmacy operations from little to no automation to customized systems that optimize productivity allows us to guide those just starting their automation journey. We’ll assess your needs, make recommendations that support your business goals, integrate your chosen solutions into your existing processes, and provide the training and support essential to ensure you get the most out of your automation investment.

Ready to get started? Contact Tension Packaging & Automation today to discuss your distribution needs.

SLAM: A Brief History (And How It Can Help Your Fulfillment Center in 2024)

tensionapdev on January 18, 2024

SLAM (Scan-Label-Apply-Manifest) automation streamlines the final steps of order fulfillment by improving throughput, reducing labor costs, and ensuring consistent accuracy in package labeling and manifesting, helping fulfillment centers meet growing customer demands with speed and efficiency.

With more and more transactions being conducted online, customers’ expectations for rapid and accurate fulfillment of their orders are at an all-time high, thanks in part to the increasingly sophisticated technology that allows distribution and fulfillment centers to keep up with demand. Of course, those anxiously waiting for a package to land on their doorstep might not be that interested in the process behind getting them the items they purchased successfully. However, if you’re wondering how your fulfillment center is going to take the next leap to keep growing numbers of customers satisfied, understanding how SLAM automation can benefit you is essential.

What Does SLAM Mean?

The acronym SLAM stands for Scan-Label-Apply-Manifest—the activities that take place after items have been packaged but before they’re put into the hands of the carrier entrusted to get it to its destination. This last 100 feet of the order fulfillment process includes numerous steps that introduce opportunities for delay and error when you must rely solely on manual labor. Wrong label on the package. Miscalculated dimensions that route the package to a more expensive shipping option. Repetitive tasks that increase the risk of workplace injuries for your employees as well as taking up valuable time that could be spent on higher-level tasks.

Where did the acronym SLAM come from? The term comes from Amazon, which developed the process. Given how heavily the company’s business model relies on fast and accurate fulfillment of orders to meet customer expectations (think about the last time you grumbled because your Prime order didn’t arrive until late in the evening!), and this fact isn’t that surprising.

What Does SLAM Do?

A full SLAM line starts by scanning the package, identifying it through the label attached during packaging, commonly called an LPN (license plate number). The actual weight can be verified against the expected weight, and the package can also be measured for its dimensions (DIMs) to help rate shop for the least expensive carrier. Then a carrier-compliant shipping label is created and applied. That label and the LPN are scanned to ensure a match, and then the package is sent to manifesting. If any discrepancies or errors are detected in weight or labeling, the package is diverted for special handling.

Depending on the needs of your fulfillment operation, you can have different versions of a SLAM line that handle only the steps you need automated. For example:

  • Print and Apply line only
  • DIM Scale only
  • Print and Apply, Scale only
  • Print and Apply, Scale, and Manifest (full SLAM line)

This flexibility allows you to configure your setup in the way that provides the most advantage to your business.

What Are the Benefits of SLAM?

When you use a SLAM line to help automate order fulfillment tasks, you can expect:

  • Improved throughput: Automation with built-in accuracy checks keeps packages moving for speedier throughput, boosting your ability to deal with surges of high demand.
  • Reduced labor: Strategically deploy your valuable workforce to where their expertise is really needed and ensure that your order fulfillment won’t be held back by a lack of personnel.
  • Consistent accuracy: Save money by reducing errors that can cost you on shipping fees and returns.

If your fulfillment center has been straining to keep up with orders in 2023—or if you’ve missed the mark more than once and have the customer complaints to show for it—now is the time to discover how a SLAM line can make your operation more efficient, expand your capacity, and reduce costs in 2024.

Custom Automation Solutions

At Tension Packaging & Automation, we’re experts at creating the right automation solutions to meet your unique requirements and business goals. We don’t just design, build, and install automation solutions—we provide the training, service, and support you need to get the most out of your investment. To learn more about how a customized SLAM line can help your fulfillment operations level up in 2024, contact us here today.