FLEXIBLE AUTOMATED SOLUTIONS – DRIVING OPERATIONAL SUCCESS

The Future of Packaging: How Automated Solutions are Transforming Co-Packing and Re-Packing Processes

As logistics operations become more intricate, automation — including advanced robotics — offers a robust and versatile powerhouse of automated packaging solutions needed to handle high volumes of goods with efficiency, accuracy, and care.

With many industry sectors reliant on fast order packing to meet tight delivery deadlines, co-packing and re-packing operations have become a highly competitive marketplace, one where the integration of smart packaging automation and robotic solutions can make the all-important difference.

What is Co-Packing?

Co-packing, also known as contract packaging, is a process that involves assembling and packaging products into their final, retail-ready form by a specialist outsourced co-packing provider. This can include combining multiple products into one single packaged item, adding promotional inserts, or creating seasonal gift sets using a variety of packaging systems and packaging materials.

What is Re-Packing?

Re-packing occurs when products need to be modified after initial packaging. This often happens due to labelling changes, compliance requirements, or adapting to different retail specifications. It may involve changes in packaging size, packaging design, or even shifting from primary packaging to secondary packaging.

Both co-packing and re-packing play crucial roles in ensuring that products reach consumers in the right format and condition, enabling the fast and efficient handling of packaged goods, and minimising waste, shipping costs, and the overall environmental footprint.

How Robotics Improves Efficiency in Co-Pack and Re-Pack Processes

Automation has become a game-changer in warehouse and logistics operations with the widespread use of robotic packaging machinery now deployed to enhance efficiency, improve accuracy, and increase the speed of order packing and shipment. Here we highlight how robotics are transforming co-pack and re-pack operations through:

Robotics

Robotics for Primary Food Handling Tasks

Increased Throughput

Robots operate continuously without fatigue, ensuring faster packaging throughput for high-volume tasks. They can also operate in temperature-controlled and cold storage environments and have lower lighting requirements which reduces energy consumption, material costs, and the associated carbon footprint.

Improved Accuracy

Automated packaging systems that are equipped with advanced vision and software technologies minimise errors in product placement, labelling, and sorting. This enhances productivity and improves product integrity in handling, leading to better overall operational efficiency across the entire supply chain.

Labour Cost Reduction & Safety

Reducing dependence on manual labour helps cut operational costs while maintaining high-quality packaging standards. Allowing robotics to handle repetitive and high-volume tasks also improves safety and ensures compliance with safety regulations.

Adaptability to Market Changes

Robotics can swiftly adapt to complex packaging requirements, enabling businesses to respond faster to market and consumer demands through lean packaging environments and packaging flexibility.

Scalability

Robots and automated packaging systems can be upscaled quickly and efficiently to offer the agility needed for both planned and sudden business growth across co-pack and re-pack activities.

How Industries Benefit from Automated Co-Packing and Re-Packing

Co-packing and re-packing continue to be instrumental in several key industries in the UK, providing significant benefits from integrated robotic packaging automation solutions:

Food & Beverage

Ensuring precise portioning, labelling compliance, shelf-ready packaging, and seasonal promotional packaging while maintaining product integrity.

Pharmaceuticals & Healthcare

Guaranteeing stringent quality standards, tamper-proof sealing, and accurate labelling within an efficient packaging environment.

Retail

Enabling manufactured items to be reconfigured into shelf-ready or right-sized packaging and ready for retail either in-store or online.

E-commerce

Enhancing the efficiency of order fulfilment and packing stations by automating gift-wrapping, product bundling, and returns processing through smart workflows.

Consumer Electronics

Facilitating delicate handling and protective packaging of high-value products using advanced packaging solutions.

Types of Robotic Solutions Used

There are a number of automated packaging solutions that have been revolutionising co-packing and re-packing operations in UK warehouses and logistics centres. From robotic picking arms to collaborative robots, these advanced products are instrumental in delivering cost savings and time efficiencies across smart packaging automation.

Robotic Arms

Robotic arms are pivotal in automating tasks such as picking, placing, assembling, and sealing products with high levels of precision and speed. Robotic pick and place systems can be configured with various end-of-arm tooling options, accommodating applications such as multiple tool changes, packing of products, or bin picking. These systems are designed to align with specific packaging responsibilities across a broad range of sectors.

Automated Guided Vehicles (AGVs)

AGVs are employed to transport goods efficiently across warehouse floors, minimising the need for manual handling and streamlining the process flow of inventory. Working autonomously, AGVs offer an agile and scalable solution to repetitive material handling tasks that enhance supply chain efficiency.

Vision Systems

Advanced vision systems, often integrated with robotic arms, use AI-driven cameras to detect product orientation, identify defects, and ensure quality assurance during the packaging process. Combining vision systems with robotics enables precise technology in identifying, picking, and packaging various items, thereby improving the accuracy of order fulfilment.

Collaborative Robots (Cobots)

Cobots are designed to work alongside human operators, assisting in tasks such as custom packing and intricate product assembly. Cobots are highly effective in packaging operations, where they optimise space utilisation and ensure secure packaging within a lean packaging environment. Additionally, cobots can handle labelling and sealing, fully automating the packing process, reducing the need for manual labour, and minimising additional costs during transit.

Robotic Palletising Systems

Robotic palletisers automate the stacking and organising of products onto pallets, improving speed, consistency, and productivity in logistics operations. These packaging machines are capable of handling a wide variety of product types and sizes, using different pallet patterns to ensure the stability of the load, and optimising the use of larger containers or secondary containers.

By integrating one or a system of advanced robotic machine systems, UK warehouses can significantly enhance their co-packing and re-packing processes. This integration leads to optimal packaging lines, increased efficiency, accurate workflow integration, and greater adaptability in meeting evolving market demands across a range of industries.

As the UK’s packaging industry and manufacturing industry continue to evolve, packaging automation is set to play an increasingly significant role in co-pack and re-pack operations. As highlighted above, a comprehensive range of innovative packaging lines and packaging equipment is widely available to warehouse operators of all sizes. These systems offer a digital solution to streamline packaging operations, reduce transport costs, and free up valuable warehouse space. The future of co-pack and repackaging services lies in intelligent automation and smart manufacturing, enabling more streamlined, accurate, and cost-effective packaging development that is fit for purpose.

From repacking requirements to bespoke packaging solutions and systems to industries wanting improved supply chain operations, advanced packaging systems now support the entire workflow and help businesses achieve sustainable supply chains with reduced transportation costs and environmental impact. With extensive experience and experienced teams, co-packing companies can now deliver a comprehensive service that ensures quality packaging through box processes, meets high repacking standards, and supports business growth through effective contract packing services.