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How We Helped an E-Commerce Clothing Retailer Increase Fulfillment Velocity & Automate Packaging Workflows
SealedAir Flow Wrapper
Ventable Stretch Wrap
We were approached by a fashion retailer that was expanding their e-commerce reach and looking to upgrade their packaging equipment. The client was looking to resolve workflow inefficiencies that were slowing down fulfilment and hurting their bottom line. The customer was sending out over 500,000 mailers (in three different sizes) a year and sending 2,000 on an average day. The packout area was comprised of 15 employees during peak hours. Within these pack stations, employees were packing by hand - including adhering printed labels and logos to the mailers.
The challenge for Gertex Solutions was to deliver an automated packaging system to the client that could both improve the workflow of their end of line packaging processes, as well as rapidly realize a return on investment from the machine for the company.
We were brought on site to audit the current packaging workflows and processes of the client. After inspection, Gertex Solutions followed up with a a questionnaire to the client that focused on three basic areas of their current fulfillment process:
1. Volumes, Sizes, Costs
2. Packing Stations, Employees, Peak & Non-Peak Hours
3. Specifications Needed in New System
From the on-site audit and the detailed questionnaire, our packaging consultant was able to visualize what the client's needs were and how we could best improve their workflows. Furthermore, the data within the questionnaire allowed for Gertex Solutions to help visualize how much savings in (cost, time, labour, etc.) could be saved for the client. It allowed Gertex to provide a real-time expectation of how quickly the solution could pay for itself.
After various types of ROI testing, it was clear that the Sealed Air FloWrap Automated Mailer System was exactly what the client needed. This horizontal systems inducts product at a speed of up to 25ppm using a continuous motion seal jaw, applies a shipping label all while tracking and verify each order going out the door accurately. This is 4 to 5 times faster than your conventional vertical bagger or 20-25 times faster than manual packout and can right size the length of each pack on the fly without setting changes. The labour savings would allow the client to reallocate resources to other parts of the business to continue pushing orders out the door faster, accurately, and waste free.
When focusing on your cost to serve more than 80% consist of freight and labor. With labor shortages at an all-time high and eCommerce demands pushing us past our capabilities how can we adapt to these challenges. As a Sealed Air valued partner you have access to our knowledge and resources that tackle the most complex challenges in the fulfillment space. With our core focus being on reducing damage, optimizing the cube of a pack, increasing fulfillment velocity, and most importantly enhancing the customer experience we know we can help take your operations to the next level of fulfillment excellence.
Why Choose the FloWrap Sealed Air Automated Bagging System
Ecommerce and Fulfillment Short-Run
Durable Home Goods
The FloWrap horizontal bagging system was the perfect solution to our client's packaging needs. Gertex was able to deliver an amazing improvement in the workflow efficiencies of the retailer. The packs per minute increased by over 600% with the overall daily capacity ballooning 1553%. Additionally, the all-in cost per pack was reduced dramatically (87%), which allowed for the FloWrap Packaging System to pay for itself within two years.
PPM per Operator
Cost per Pack
650% Increase in PPM Speed
Daily Output Capacity Increase by 1553%
Investment Payback (24 months)
Repositioned over 200 Hours of Labour a Week
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