Automation In Focus: Optimising Packaging Operations Through End-of-Line Automation by Ranpak
We are pleased to spotlight AutomationSG member Ranpak and its end-of-line automation solutions that help businesses improve packaging efficiency while supporting sustainability goals.
Fulfilment operations face three key challenges: rising labour costs, increasing sustainability requirements, and the need to scale throughput efficiently. According to Ranpak, designing automation from the end-of-line forward establishes a seamless and scalable flow that integrates with warehouse systems.
Ranpak's focus on end-of-line automation is a natural extension of its expertise in packaging materials and solutions. Through decades of experience in packaging processes, Ranpak has translated this knowledge into advanced automation solutions that support customers' operational needs.
According to Ranpak, end-of-line automation should not be an afterthought. It should be the starting point. Designing automation from the end-of-line forward establishes a seamless and scalable flow that integrates with AS/RS and warehouse systems, maximising the ROI of the entire automation footprint.
Ranpak's automation solutions address key challenges by automating repetitive tasks such as box erection, void-fill dispensing, labelling, and sealing. This enables businesses to redeploy labour to higher-value roles while improving operational efficiency
The company's technologies also rightsize every package by reducing wasted space and optimising protective materials. This helps lower shipping costs, reduce product damage, and support compliance with evolving sustainability regulations.
One notable implementation involved a publishing and distribution client that had successfully implemented an advanced Goods-to-Person (G2P) picking system but encountered downstream bottlenecks in its packing operations.
The packing process was challenged by manual tape application, excessive void-fill usage, and a large variety of box SKUs. This complexity affected quality and operational efficiency. It also resulted in bulky pallets with significant unused space, higher shipping costs, and reduced warehouse efficiency.
Ranpak stepped in to transform this end-of-line process into a standardised and high-throughput operation. Driven by the streamlined workflow of the Cut’it!™ EVO, bulk packing efficiency increased by 42%. Meanwhile, the simplified footprint of the Flap’it!™ system led to a 65% increase in non-bulk packing efficiency.
(Flap’it!™ automates the packing of small products for e-commerce and logistics operations. Integrated cushioning bumpers help reduce transport damage and product returns.)
The solution also simplified operations by replacing a large inventory of boxes with just three standardised carton types: the Cut’it box, Cut’it lid, and Flap’it box. This consolidation enabled uniform stacking profiles, making palletisation faster, safer, and more predictable.
By eliminating plastic tape and reducing void fill, the client achieved 100% curbside recyclability for end consumers while reducing repetitive manual handling on the warehouse floor. This allowed employees to transition into higher-value roles, upskill into automation management, and work in a safer environment.
Ranpak's experience supporting large-scale operations, including global companies such as Amazon and IKEA, has reinforced the importance of scalable automation and data-driven insights. According to Ranpak, gathering rich data and distilling operational insights is at the heart of its approach, helping businesses understand individual machine performance as well as the success of broader integrations.
Looking ahead, Ranpak sees a data-driven warehouse where the effects of automation are quantified and scaled as the foundation for broader industry adoption. Its approach is grounded in meaningful throughput, sustainability, and cost improvements backed by data.
Learn more about Ranpak’s automation solutions:
Cut’it!™ EVO: https://www.ranpak.com/automated-solutions/evo-cutit/?utm_source=enewsletter&utm_medium=email&utm_campaign=automationgosg