Modular Components of Pack Station Solutions
These are the key elements that work together to bring automation and efficiency to your packaging line. Consider them the specialized tools that ensure your products are packaged quickly, accurately, and safely. TPC offering ROI-backed solutions.
Case Formers
These automated units efficiently fold and shape pre-made boxes. Case formers offer adjustable settings, size adaptability, and straightforward maintenance, making them ideal for operations requiring flexibility.
They usually pair with Ergonomic Box Stands, ensuring flat boxes are always within reach to reduce strain while boosting operational efficiency.
Case Sealers
Once your boxes are formed, case sealers ensure they are securely closed, typically using tape or glue. They come in various configurations to handle different box sizes and production speeds, ensuring product protection throughout the distribution process.
Case Identification Systems (Labeling & Coding)
Accurate labeling is crucial for efficient supply chain management. Our automated packaging solutions can integrate two primary identification methods. While both case identification technologies are effective in a pack station, the best choice will depend on the specific application and customer requirements.
These systems apply pre-printed labels with high precision, ensuring accurate product identification and tracking. While they offer excellent accuracy and print quality, they may be less adaptable to frequent label changes.
These systems print directly onto boxes, providing flexibility for label content changes and reducing labeling costs. While they offer greater adaptability, they may have limitations in print quality compared to pre-printed labels.
Time Study
In today’s world of manufacturing, TPC is focused on finding ways to work smarter, not harder. When reviewing your facility’s end of the line process, the packaging of your product can become a pinch point that prohibits your upstream process from achieving its optimum effectiveness. Uncovering a way to address every-day issues such as the amount of labor required, packaging efficiency, identifying your cases, and maintenance can eliminate that stopgap and maximize your line’s productivity rate.
That’s where Pack Stations come in. Whether you’re looking for a fully automated system or something a bit more hands-on, these customizable solutions are designed to make your packaging process much smoother. These modular systems combine various packaging functions into a single, integrated unit, reducing the reliance on manual labor and its associated risks. This will result in streamlined workflows, happier employees, and more products shipped at reduced costs.
Pack Stations: Technical Overview
The core components of our Pack Stations encompass any & all operational mechanisms in your existing manual setup:
Keeping Things Moving
Accumulation tables and accumulation conveyor play a crucial role in optimizing product flow and ensuring smooth transitions between the different stages of the packaging process.
Bagging It Up
If your products require bagging, Pack Stations can automate this process, increasing efficiency and reducing material waste.
Building Boxes
Case formers are responsible for unfolding and assembling flat corrugated cardboard into a three-dimensional box structure.
Shaping Up for Success
Once the boxes are erected, they are precisely shaped and formed by an automated case former.
Sealing the Deal
Securely sealing the cases, typically with tape or glue, ensures your products are well-protected during transit and storage.
Case Identification
Clear and accurate labeling is essential. This can involve applying pre-printed labels or directly printing information onto the cases for traceability and inventory management.
Maintaining a Tight Fit
For added protection and a more polished look, shrink systems can be integrated as well.
A Pack Station brings together these functions in a tailored system to meet your specific needs, offering a cohesive and efficient approach to packaging.
Advantages of Automating Your Packaging System
Labor Cost Reduction
Pack Stations reduce the need for manual packaging, freeing your team up for other tasks and providing ROI benefits over time. Fewer required hands can lead to significant savings, especially in environments where finding and retaining skilled workers is a challenge. In a case study involving a retail coffee roasting company, the implementation of a semi-automated Pack Station resulted in the reallocation of two employees who were previously packaging entire crates of coffee beans by hand, ultimately leading to significant cost reductions and increased throughput.
Efficiency
Automated processes mean you can package more products in less time. In the same case study, our Pack Station solution enabled the coffee retailer to increase their packaging rate from 5 boxes per minute to 8 boxes with the same number of employees.
Operator Movements
Pack Stations are engineered & designed with ergonomics in mind, reducing strain and the risk of injuries for your team. By optimizing workspace layout, minimizing repetitive movements (or picks), and decreasing human touchpoints, our automated packaging solutions contribute to a healthier and safer work environment.
Accuracy
Automated systems eliminate human error, guaranteeing consistent and precise packaging outcomes. This can lead to reduced waste, improved product quality, and enhanced brand reputation.
Scalability
Pack Stations can be customized to your needs and easily scaled as your business grows allowing you to respond to evolving market demands and customer needs without requiring a complete overhaul of your packaging infrastructure. The system has a small footprint and is modular, allowing customers to add automation as they grow, such as case packing robots and palletizing robots.
Picking the Perfect Pack Station
The best Pack Station for you depends on a few things:
- What are you packaging? The size and type of your products matter.
- How much are you packaging? We need to know your volume to match you with the right speed and capacity.
- How much automation do you want? We offer everything from fully automated to semi-automated, depending on your budget and needs.
- How much space do you have? We’ll make sure the Pack Station fits comfortably in your facility.
- What’s your budget? We have options for every price range.
Our team of experts will work with you to design a system that’s just right for you.
Pack Stations: Helping Businesses of All Shapes and Sizes
No matter what industry you’re in, Pack Stations can help you upgrade your packaging process:
Upgrading to Pack Stations with TPC
Pack Stations represent a significant leap forward in packaging technology. They’re not just about automating tasks; they’re about creating a smarter, more efficient, and more adaptable packaging process. TPC’s automated packaging solutions empower businesses to focus on what they do best: creating and delivering exceptional products.
But the benefits go beyond the bottom line. By automating repetitive tasks and optimizing ergonomics, Pack Stations reduce the risk of injuries and strain, leading to a happier and more productive workforce.
If you’re ready to experience the transformative power of Pack Stations, reach out to TPC Packaging today. Our team of experts will work with you to design a custom solution that meets your unique needs and helps you achieve your business goals.