Choosing packaging automation now means considering operational performance alongside evolving packaging requirements. For eCommerce brands preparing for Extended Producer Responsibility (EPR), reducing excess packaging is an actionable step toward better material efficiency and regulatory readiness. The right system should support these goals while meeting the demands of the operation’s product mix, throughput and product protection requirements.
The cost of delaying automation in your business is causing more financial distress than you may think. Access the automation and packaging solutions for your operation today!
Tension had the pleasure of attending the 2026 MODEX show in Atlanta this year. From April 13-16, we connected with customers, partners, and fellow industry leaders. This blog outlines some of our key takeaways.
MODEX 2026 made one thing clear: the industry is moving faster, thinking smarter, and demanding more from automation. Across every conversation, one theme consistently surfaced. How to do more with less, without adding complexity.
Hear from three of our subject matter experts on what to look out for in packaging and automation this year.
Automation Has Shifted from Optional to Essential
“The biggest takeaway is that automation is not a ‘nice to have’—it’s a requirement. We are seeing customers being much more strategic in their purchases. They are not looking for one-off pieces of machinery, they want to see how it fits into their entire system.”
— Jim Herbert, VP & GM of Tension Packaging & Automation
That sentiment echoed across our conversations. What stood out even more was how companies are approaching automation. There is a clear shift toward practical systems that can be deployed quickly and scaled over time.
Want to know more about how to start small and scale with confidence?
Robotics were everywhere at MODEX, but the real story was the intelligence layered on top. AI-driven optimization, adaptive workflows, and smarter decision making are reshaping fulfillment operations. When paired with packaging automation platforms like fitPACK500™ and HPS300, these technologies create connected workflows that are faster, more efficient, and more responsive.
See how fitPACK500™ is driving smarter packaging outcomes:
Labor challenges remain one of the most pressing issues. Companies are struggling to find and retain qualified workers, leading to inconsistent operations.
At the same time, rising costs and economic uncertainty are pushing organizations to rethink how they operate. Automation is about more than efficiency. It is about stability and long-term sustainability.
Explore automation strategies built for today’s labor challenges:
MODEX 2026 offered a clear preview of where the industry is heading. Not toward isolated machines solving single tasks, but toward connected systems working together intelligently.
The opportunity is not just to automate. It is to automate with purpose.
Start building a smarter, more connected operation by getting in touch now.
Sustainability in high volume packaging is no longer a tradeoff. The expectation is clear: reduce waste, lower environmental impact, and maintain the speed and precision operations depend on. At Tension Packaging & Automation, sustainability is built into our daily operations, combining material innovation with automation that drives measurable efficiency.
1. Right-Sized Packaging Helps Eliminates Excess
Packaging should fit the product, not the other way around. Automated right-size packaging reduces excess material, eliminates unnecessary void fill, and improves cube efficiency across every shipment. The result is less waste, lower shipping costs, and a more efficient operation from pack out to delivery. Read our Sustainability Promise.
2. Recycled Materials Engineered for Performance
Sustainable materials must perform at scale. Recycled polybags, including C-fold configurations, are designed to run consistently in high-speed automated environments while incorporating recycled content. This allows organizations to reduce their environmental footprint without introducing risk to throughput or system reliability.
3. System Level Efficiency That Reduces Impact
Sustainability is driven by how the entire system performs. Integrated automation reduces manual handling, streamlines workflows, and minimizes variability across operations. Fewer touchpoints and optimized processes lead to reduced waste, lower energy usage, and a more controlled, efficient packaging environment.
Tension continues to expand sustainable packaging solutions through collaboration with material partners. This includes recyclable padded mailers and paper-based alternatives that reduce reliance on plastic while maintaining durability and protection during distribution.
These options allow organizations to align packaging choices with broader sustainability goals without sacrificing performance.
You Are What You Repeatedly Choose
Sustainable packaging is not a single decision. It is a system level strategy that requires the right materials, the right automation, and the right partner.
Explore how Tension Packaging & Automation can help you reduce waste, improve efficiency, and scale smarter with sustainable solutions.
Tension Packaging & Automation will showcase the company’s latest advances in automation and celebrate Tension Corporation’s 140th anniversary during MODEX 2026 in Atlanta, April 13-16, 2026.
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, ourfitPACK500TM—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.
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.
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.
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.
