Implementing mobile robots to accelerate e-commerce fulfillment picking necessitates ensuring that packaging operations are equally efficient. iForce, a third-party logistics (3PL) company based in Rugby, United Kingdom, sought to synchronize and automate its picking and packing processes at its fulfillment center serving The Works, a prominent retailer of toys and stationery.
By adopting an automated packaging solution from Sparck Technologies, iForce achieved the necessary speed and reliability in packaging to complement its optimized pick processes. Additionally, the deployment of autoboxing technology enabled the creation of custom-sized cartons, enhancing the unboxing experience for e-commerce customers.
Central to iForce’s strategy is prioritizing customer service, emphasizing efficient order fulfillment and timely delivery of well-packaged items to drive repeat sales. However, faced with labor shortages and escalating costs, meeting fulfillment targets during peak periods posed challenges. To overcome these hurdles, iForce undertook a comprehensive initiative to invest in advanced warehouse automation, with full support from The Works.
The automation strategy comprised three key elements: robotic goods-to-person order picking, robot-assisted picking, and automated packaging systems. Crucially, seamless synchronization among these components was essential. Recognizing the potential of automated packaging with autoboxing technology to enhance the unboxing experience while reducing labor requirements and boosting throughput, iForce opted for Sparck Technologies’ CVP Impack machine.
Neil Lavercombe, iForce’s business planning manager, underscores the advantages of Sparck Technologies’ auto fit-to-size packaging principle over traditional box-closing systems. Installation of a dual infeed CVP Impack machine at iForce’s Rugby warehouse in June 2022 marked a significant milestone, enabling uninterrupted order processing from tote induction to the creation of perfectly sized, labeled packages, just in time for The Works’ busy autumn peak season.
Implementing mobile robots to speed up e-commerce fulfillment picking requires ensuring that packaging operations can match this pace. For iForce, a third-party logistics (3PL) company based in Rugby, United Kingdom, synchronizing and automating picking and packing processes at its fulfillment center serving The Works, a prominent retailer of toys and stationery, was a priority.
By adopting Sparck Technologies’ automated packaging solution, iForce achieved the necessary speed and reliability in packaging to complement its optimized pick processes. The incorporation of autoboxing technology enabled the creation of custom-sized cartons, enhancing the overall unboxing experience for e-commerce customers.
Customer service is paramount in iForce’s strategy, emphasizing efficient order fulfillment and timely, well-packaged deliveries to drive repeat sales. However, with labor shortages and escalating costs prevalent in the industry, meeting fulfillment targets during peak periods posed significant challenges. To address this, iForce undertook a comprehensive initiative to invest in advanced warehouse automation, with full support from The Works.
The automation strategy comprised three key elements: robotic goods-to-person order picking, robot-assisted picking, and automated packaging systems. Ensuring seamless synchronization among these components was crucial. Recognizing the potential of automated packaging with autoboxing technology to enhance the unboxing experience while reducing labor requirements and increasing throughput, iForce opted for Sparck Technologies’ CVP Impack machine.
Neil Lavercombe, iForce’s business planning manager, emphasized the advantages of Sparck Technologies’ auto fit-to-size packaging principle over traditional box-closing systems. The installation of a dual infeed CVP Impack machine at iForce’s Rugby warehouse in June 2022 marked a significant milestone, enabling uninterrupted order processing from tote induction to the creation of perfectly sized, labeled packages. This implementation was completed just in time for The Works’ busy autumn peak season, showcasing iForce’s commitment to efficiency and customer satisfaction.
Speed, throughput, and reliability constitute the fundamental characteristics of fit-to-size autoboxing technology, a critical feature considering that during peak periods, The Works experiences approximately 70% of its e-commerce parcels being automatically generated. This necessitates packaging automation that can adapt to varying order profiles while efficiently accommodating a diverse range of line items.
“Order profiles, including the number of items per order and the physical size of orders, can fluctuate throughout the year, ranging from typical e-commerce profiles with one or two items per order to those with 10 or more items,” explains Lavercombe. “The CVP Impack consistently produces appropriately sized packaging for our diverse array of orders.”
Custom-sized packaging tailored to each order ensures that customers receive compact, well-fitted boxes, promoting convenience, reducing concerns about excessive packaging, and conveying a positive environmental message. Additionally, the snug fit of fit-to-size corrugate packaging minimizes item movement, providing enhanced protection without the need for additional bubble wrap or void-fill materials.
“Our aim was simplicity,” notes Lavercombe. “The packaging machine needed to seamlessly integrate with both our existing manual processes and our new robotic systems—here, the straightforward design of the Sparck machine proved ideal for us. Moreover, the installation process was remarkably smooth. The machine arrived on a Monday morning, and by the following Friday, boxes were rolling off the line. Within just two weeks, it was fully operational.”
The fit-to-size autoboxing technology embodies essential attributes such as speed, throughput, and reliability, crucial for The Works, especially during peak periods where approximately 70% of its e-commerce parcels are automatically generated. This demands packaging automation that can adapt to fluctuating order profiles and accommodate a wide range of line items efficiently.
“Order profiles, including the number of items per order and their physical size, vary throughout the year, ranging from typical e-commerce orders with one or two items to larger orders with 10 or more items,” explains Lavercombe. “The CVP Impack consistently delivers appropriately sized packaging tailored to our diverse order requirements.”
By providing custom-sized packaging for each order, customers receive compact, well-fitted boxes, enhancing convenience, reducing concerns about excess packaging, and conveying a positive environmental message. Furthermore, the snug fit of the fit-to-size corrugate packaging minimizes item movement, ensuring better protection without the need for additional bubble wrap or void-fill materials.
“Our goal was simplicity,” notes Lavercombe. “The packaging machine had to seamlessly integrate with both our existing manual processes and our new robotic systems—here, the straightforward design of the Sparck machine proved ideal for us. Moreover, the installation process was remarkably smooth. The machine arrived on a Monday morning, and by the following Friday, boxes were rolling off the line. Within just two weeks, it was fully operational.”