Allpack Excels with Void Fill Machine Installation at East Midlands Distribution Centre

Allpack Packaging Ltd is a leading UK-based supplier of packaging materials, machinery, and solutions. It is renowned for providing innovative and sustainable packaging solutions to businesses across various industries. As a trusted partner for large-scale operations, it focuses on optimising its clients' packaging processes by providing cost-effective, eco-friendly, and efficient solutions.

The Challenge

In 2024, Allpack was approached by a major e-commerce and logistics company operating a large distribution centre in the East Midlands. This was due to an endorsement from a pre-existing business relationship built upon excellent customer services, experienced over many years.

The client, which handles thousands of packages daily, faced increasing operational pressure due to rapid business growth. With the rise in online orders, the volume of goods being shipped was reaching unprecedented levels, leading to packaging bottlenecks. The key pain points included:

- Packaging Efficiency: Manual processes for filling void spaces in boxes slowed down fulfilment, increasing labour costs.

- Product Protection: Inconsistent use of protective packaging material resulted in damaged goods, leading to customer dissatisfaction and increased returns.

- Sustainability Goals: The client sought to reduce its environmental impact by adopting more sustainable packaging solutions, minimizing waste, and using recyclable or biodegradable materials.

Allpack’s Solution

Based on the client’s specific void fill machine requirements, Allpack conducted a comprehensive analysis and audit of the client’s packaging operations, that helped identify how the packing process could be significantly optimized. Allpack was then able to recommend a set of advanced, automated void fill machines that would seamlessly enhance their current operations, concentrating on installing paper void fill systems using fanfold paper, to maximise space within the packing area. The paper void fill systems use recycled paper to fill void spaces in packages, ensuring products are securely packed while minimising the use of non-sustainable materials like plastic air pillows.

Implementation Phase

The project involved the installation of 10 Grip Superflow dispensers, integrated across different packaging stations in the East Midlands distribution centre. The key stages of implementation included:

1. Custom Configuration: The machines were customised to suit the specific pack bench configurations, to enhance the process flows within the packing area. Allpack’s team worked closely with the client to determine the appropriate settings for the different order types to ensure maximum efficiency.

2. Seamless Integration: The machines were integrated into the client’s existing fulfilment workflow with minimal disruption. Allpack’s engineers ensured that the machines could work alongside the existing packaging automation systems, with the installation of the machines undertaken by our in-house packaging engineering team.

3. Employee Training: To ensure smooth operations, Allpack provided comprehensive training to the distribution centre’s packaging team, enabling them to operate the new machines effectively.

4. Ongoing Support: Allpack has set up a dedicated support team to provide regular maintenance and technical support, ensuring the machines operate at peak performance without any downtime.

Results

The installation of the new void fill machines yielded immediate and tangible benefits for the East Midlands distribution centre:

1. Improved Efficiency: With automated void fill machines, the centre saw an increase in packaging speed, reducing manual labour and packaging time per order. This allowed the client to meet growing demand without increasing headcount.

2. Enhanced Product Protection: The standardised void fill solutions reduced the risk of damaged products, leading to a decrease in return rates due to insufficient packaging.

3. Sustainability Gains: By replacing plastic void fill materials with recycled paper and biodegradable alternatives, the client achieved a reduction in non-recyclable packaging waste. This not only helps to meet their sustainability targets but also resonates positively with eco-conscious customers.

4. Cost Savings: The shift from manual processes to automated systems resulted in long-term savings through reduced material waste, lower labour costs, and fewer returns due to damaged goods. The client is poised to make substantial cost savings over the life of the project. 

Conclusion

Allpack successfully transformed the packaging process for this major distribution centre in the East Midlands. The client significantly improved efficiency, reduced waste, and enhanced customer satisfaction through the strategic installation of automated void fill machines. This project exemplifies Allpack’s process intelligence credentials and commitment to providing tailored, sustainable solutions that address the evolving challenges of large-scale logistics operations.

Process Intelligence is a key pillar of Allpack, where we use process flow data and analytics to inform clients of critical information to enhance their business decisions through customised data reports, product analysis and process designs that improve your warehouse operation and reporting requirements. Contact us today to see how we can help you enhance your existing packing operations, via email - sales@allpack.uk.com or telephone on 01543 396700.