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Shining a light on automation

By eliminating manual assembly from its packaging line, Peterson Manufacturing Company has increased sales, lowered production costs, and saved money on materials.

Management at Grandview, MO-based Peterson Manufacturing Co. recently decided it was time to automate the packaging line for its 440 Series trailer lighting kits. The trifold, hinged clamshells previously used to house the multicomponent kits had a button-snap closure that employees complained hurt their wrists.

“One major reason to automate the packaging for the kits was ergonomics,” says Tobe Tennyson III, manager of manufacturing engineering at Peterson. “All the packaging for our trailer lighting kits was done manually and the hinged clamshells we were using hurt employees’ wrists. We were getting one or two serious complaints a year, and that wasn’t good.”

Thanks to new two-piece blister packaging from Klöckner Pentaplast and a 20-station radio frequency sealing machine from Alloyd, Peterson has seen orders for its product increase while it has lowered production costs and increased materials savings.

“It’s a much better looking package, I think, and so do others,” Tennyson says. “It’s popular in retail circles. We produced tens of thousands with the old trifold clamshell packaging. With this new design, we’re getting additional ‘pop’ from our planogram, which has boosted sales considerably.”

Tennyson credits much of the package’s improved aesthetics to the vinyl rigid film from Klöckner. He says the sleek new look of the packaging recently contributed to a decision by Peterson’s biggest customer, who recently increased their order significantly to fill out end caps.

The package’s compact size is also contributing to increased sales. The new packaging is significantly smaller than the previous packaging. For example, the dimensions for model V544, intended for trailers larger than 80”, is 2” smaller than its predecessor. In this particular pack, customers will find submersible lights, a 23’ trailer harness, 48” trunk connector, plastic license bracket, all mounting hardware, and installation instructions.

“The smaller size means that in-store display planograms can hold more SKUs, of which there are a total of five in the series,” says Mark Assenmacher, Peterson’s marketing manager.

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