Packaging stations - how to design, equip and (possibly) automate the packaging process

Estimated reading time: approx. 10 minutes

TL;DR:

• Properly organised packing stations speed up order processing and reduce errors
• Ergonomics and operator safety translates into lower absenteeism and greater efficiency
• Taking care of storage of materials (cartons, fillers) saves time and space
• Packaging automation can eliminate repetitive steps and minimise the risk of mistakes
• Cost analysis (e.g. ROI) helps decide on the profitability of robotisation at a given production scale

Table of contents

• Why are proper packing stations crucial?
• Step 1: Planning and organising the space
• Step 2: Choosing the right equipment for the job
• Step 3 Ergonomics and occupational safety
• When is it worth automating packaging stations?
• How does the robotisation of packaging work in practice?
• How to assess the profitability of investment in robotic packaging?
• Practical tips for implementing packaging stations
• Summary - key benefits and recommendations
• Encouragement for further action

Introduction

Packaging stations are becoming an increasingly important part of efficient logistics and production. Especially at a time when companies are looking to streamline workflows and minimise operating costs, a well-planned packing station is of colossal importance. In this article, we will discuss how to design and organise an effective packing station in a company step by step. You will learn why optimum material flow and work ergonomics are fundamental, what solutions are worth implementing and when to consider automation or robotisation of this area.

If you are interested in a practical approach to the subject and want to make your company's packing area more productive in real terms, this guide is for you. We will look at how to arrange your packing area properly, what tools can help you and what mistakes to avoid. Finally, we will look at the benefits of introducing automation or robots into your packaging processes. Enjoy the read!

Why are proper packing stations crucial?

Well-designed packing stations translate into:

• Faster order processing. Redundant movements are minimised, which, with large-scale production, reduces wasted time.
• Lower operating costs. Efficient distribution of materials and tools reduces handling time, allowing the same number of staff to handle more parcels.
• Improved safety and ergonomics. By adjusting the height of the tables or the positioning of the shelves, the workplace is made more operator-friendly.
• Fewer errors and complaints. Clear organisation reduces the risk of confusion due to inadequate packaging or mixing up the contents of shipments.

In practice, if there is chaos in the warehouse or production floor, this disrupts the entire flow of goods - from picking to final box sealing and dispatch to the customer. Therefore, it is crucial to consider input flows (materials and products arriving at the packing area) and output flows (finished packages leaving the shipping department) from the outset.

Step 1: Planning and organising the space

One of the most important elements is the correct placement of the packing station within the plant or warehouse. According to Lean Management principles, it is best if the packing area is located between the storage and dispatch areas. This reduces unnecessarily long product transports and eliminates bottleneck queues at the exit of the production process.

Location and movement of goods

• Try to ensure that order picking teams have as short and easy access to packing stations as possible.
• Ensure that parcels, once packed, go 'smoothly' to the courier collection point or for onward distribution on automated lines (if installed).
• Pay attention to safety - limit crossing paths of operators and machines (e.g. forklifts) in a way that impedes workflow.

Zones dedicated to specific activities

Specialised packing stations or, in the case of a large number of different products, areas prepared for a specific type of item, can reduce handling times by up to ten per cent. This way, every employee knows where the correct cartons, filler papers or tapes are located. If the type of assortment is diverse, do not try to 'lump everything together'; it is better to develop a standard for labelling and create a separate shelf or station for each large segment of goods.

Step 2: Choosing the right equipment for the job

A correctly arranged packing station is more than just a worktop and a roll of adhesive tape. It is worth looking at the equipment from a broader perspective.

Tables and accessories

• The table should be large enough to accommodate all basic materials (cartons, fillers, labels) and possible equipment (label printer, scales).
• Think adjustable height - this allows each employee to adjust the level of the worktop to suit their needs, increasing ergonomics.
• Add shelves and holders for packaging accessories such as rolls of bubble wrap or paper. These can be mounted vertically, horizontally or in a side mount - so that the material unwinds easily.

Storage bins and shelves

• Place shelves within easy reach, preferably between waist and shoulder height - this is the zone where you put the least strain on your spine.
• Consider using dedicated racks for different sized cartons, so you can quickly pull the right size without flipping through a stack of boxes.
• Invest in bins to segregate small accessories such as warning stickers, tags and staples.

Materials organisation systems

• In large warehouses and warehouses, the 5S principle - sorting, systemising, tidying, standardising and self-discipline - will work well. This helps to keep things tidy and quickly identify the items needed.
• Label or colour-code all items: types of carton, types of filler film and tools (e.g. scissors, knives, tape). This way, every operator knows what lies where, without having to look for it.

Step 3 Ergonomics and occupational safety

Inadequate table height, lack of adequate manoeuvring space or incorrect lighting can cause health problems for staff. The result is not only high absenteeism costs, but also reduced productivity.

Height and workspace adjustment

• The optimum height is one that relieves the strain on the back. For people of average height, this is usually around 90-100 cm.
• If there are large height differences in the team, adjusting the tables (or using platforms) can sometimes be invaluable.

Lighting and safety

• Choose a bright and diffused light in the packing area - too strong shadows can make it difficult to work with small accessories.
• Avoid placing pallets and cardboard boxes on the floor in the aisles. Any obstacle increases the risk of tripping or collision with the forklift.
• Install a system of signs and pictograms (e.g. informing of the escape route), as well as the nature of the goods (e.g. "caution glass").

When is it worth automating packaging stations?

The increasing digitalisation of processes, labour shortages and growing pressure to reduce production costs are causing many companies to consider installing automated and sometimes robotic packaging lines. Many solutions already exist in the industry - from simple dispensers of packaging materials to advanced robots that self-assemble cartons, pack the product and apply labels.

Main rationale for automation

• Highly repeatable activities. The more routine, mechanical the activity, the easier it is to automate the process and achieve significant cost savings.
• High risk of human error during packaging (e.g. confusion of labels). Automatic systems guarantee consistency and precision.
• Need for increased safety. Some products may require special care. Robots can easily handle fragile goods without risking injury.

At Automation Michale, we have been designing solutions to support companies in the modernisation and integration of production lines for years. This also applies to packaging processes, which you will read more about in the section on robotisation of packaging.

How does the robotisation of packaging work in practice?

The decision to robotise packaging workstations depends on a number of factors, including the size and variety of the product range, the expected productivity or the budget available. However, a typical implementation process can be described in a few steps:

Analysis of needs and processes

• In this stage, all packaging operations are mapped: folding of packages, placement of fillers, labelling.
• Bottlenecks and areas where errors or quality deficiencies most frequently occur are identified.

Technology selection and line design

• Industrial automation and robotics specialists (from Michale, among others) advise on whether an automated packing table and simple equipment will suffice, or whether the introduction of robots (e.g. the SIASUN robotic arm) might prove better.
• At this stage, the type of gripper (if it is a robot), the vision system for recognising parts and the integration of the whole solution into the existing production environment are also defined.

Assembly, testing and training

• Once a stand has been designed and built, it needs to be tested under conditions that approximate real-world loads.
• This is followed by training for the operators so that they understand the logic behind the machines, know how to operate them and how to react in the event of any malfunctions.
• Finally, the workstation is implemented for continuous operation, controlling quality and performance parameters.

With Michale's comprehensive support, the automation of packaging processes runs smoothly and any shortcomings or failures can be quickly addressed. If necessary, maintenance and repair support is also worth considering, as automated systems and robots require periodic maintenance. For details, check out the offer service and maintenance of posts.

How to assess the profitability of investment in robotic packaging?

Many business owners are still concerned about the costs associated with implementing modern technology. It is therefore important to look at the ROI (Return on Investment). Robots, packaging machines and the accompanying infrastructure may have a rather high purchase price, but in a perspective of several months they often turn out to be an extremely profitable investment.

• Reducing the number of errors (e.g. poorly packed or incomplete shipments leads to fewer complaints).
• Reducing packaging time with increasing numbers of orders.
• Reducing staffing costs and reducing turnover among employees performing monotonous, physically exhausting tasks.

Although ROI calculators are sometimes designed for specific processes (e.g. check out the sample ROI calculator dedicated to welding), certain assumptions can be roughly transferred to the packaging area - simply by taking into account data such as labour time, hourly rates, parcel volume and the cost of errors.

Practical tips for implementing packaging stations

Below you will find a list of recommended steps to help you create an efficient and employee-friendly packing station:

1. Examine existing processes.
   - Identify bottlenecks and where the biggest errors occur (e.g. incorrect labels, inaccurately filled packaging).

2. Apply the 5S method.
   - Tidy up the space, eliminate unnecessary elements, organise what is necessary. Ensure cleanliness, standardise the layout and remember to maintain regularity.

3. Get the right tables and shelves.
   - The table should have an ergonomic top and the shelves must be within easy reach.
   - Install film and paper roll holders so that they can be easily unwound.

4. Provide operators with training.
   - This applies both to the operation of the manual workstation and to any equipment that automates the process.

5. Monitor results and make continuous improvements.
   - Measure packing time, number of errors, daily parcel volume and staff satisfaction levels. Update station layout and equipment on this basis.

6. Consider integration with other systems.
   - If you have an ERP/MES system, you can introduce real-time stock monitoring of packaging materials and, with robotisation, integration with vision systems.
   - Before deciding on robotisation, take a look at Michale's overall process automation offering: robotisation services

Summary - key benefits and recommendations

Below, in the form of brief bullet points, a set of the most important information to remember from the article:

• Properly designed packing stations speed up order handling and minimise the risk of errors.
• By skilfully using shelving, tables, shelves and accessories in the packaging area, manufacturers and retailers can significantly reduce costs.
• Ergonomics (adjustable table heights, proper lighting, load flow planning) has a direct impact on the health of employees and their motivation to work.
• Automation and robotisation of packaging workstations can support business growth and increase productivity in processes requiring high repeatability or exceptional precision.
• The implementation of modern solutions (including robots) should be considered on the basis of realistic calculations (ROI, TCO), and the need to modify existing infrastructure should also be carefully assessed.

If you need help optimising your packaging processes and want to find out how industrial technology can make your business more competitive - contact the experts at Michale Automation. We tailor solutions to the needs of both smaller plants and large enterprises, providing comprehensive implementation services and after-sales support.

Encouragement for further action

We hope that after reading this you already know the importance of packing stations and why it is worth looking at the configuration of the packing area from both an organisational and technological perspective. We invite you to explore the topic of production optimisation further:

• See how you can increase efficiency in other areas, for example by robotisation of packaging.
• If you are interested in comprehensive servicing and maintenance of the machines you have deployed, be sure to check out the offer service and maintenance of posts.
• Explore the potential of automation in different areas by visiting the robotisation services.
• Find out more about estimating the return on investment in robotisation - check out the example ROI calculator and evaluate how certain assumptions may apply to the packaging process.

Do you have questions or would you like to consult on which type of packaging station would work best for your company? Contact us for an individual proposal - from the initial concept to full implementation and after-sales care. This way, you can be sure that your packaging processes will be efficient, safe and ready for the growing demands of the market. Good luck in optimising your packing stations!

FAQ

How long does it take to implement packaging stations?
Time depends on the complexity of the processes and the degree of automation. Simple modifications to manual workstations can be implemented in a few days, while full robotisation can take several weeks to several months.

Will packaging automation work for a small business?
Yes, many solutions can be scaled according to company size and production volume. Smaller companies are increasingly implementing automation to improve efficiency and compete with larger players.

Which elements of packaging can be most easily automated?
The most common tasks that are automated are the forming of cartons, the dispensing of fillers, the sealing of packages or the affixing of labels. These tasks are repetitive, making it easy to install equipment and robots.

Does the implementation of robots involve major infrastructure changes?
It depends on the project. Sometimes it is sufficient to adapt the space and provide the necessary connections. For advanced implementations (e.g. integration with vision systems), additional modifications to the line and production space will be required.