Report: Innovative New E-Commerce at PACK EXPO Las Vegas

Ten intrepid Packaging World editors fanned out across PACK EXPO Las Vegas in October in search of packaging innovation. Here's what they found.

2 Box Sizer
Photo 2

NOTE: E-Commerce wasn’t the only area of interest at PACK EXPO. Click the links that follow to read more about innovations in:
Machinery   Materials   Controls   Pharma  Robotics

E-COMMERCE INNOVATIONS 
According to Jeff Chalovich, Chief Commercial Officer and President of Corrugated Packaging, the two clear stars of the WestRock lineup at PACK EXPO Las Vegas were both package right-sizing systems designed for fulfillment centers, DCs, and similar e-comm-oriented channels.

The first, Pak On Demand (1), is a corrugated pouch system that first 3D scans product as it approaches on a conveyor, then uses the scanned dimensions to create a custom, right-sized corrugated pouch on-demand and seal the package for shipment. Photo 1Photo 1

“The result is a highly protective package that is completely curbside recyclable,” he says. “The Pak On Demand Pouch System eliminates unnecessary void fill and shipping charges, increases pack efficiency, and lowers labor costs by automating a previously manual process.”

The system precisely cuts WestRock’s innovative KD Fold corrugated for a system that’s two to three times faster than manual packout, according to the company. The corrugated pouch carries an easy-tear strip, yet is secure during transit. For video of the pouch system in action, go to pwgo.to/5366.

For larger corrugated cases containing multiple, randomly sized products, as is common in a fulfillment center setting, WestRock offers BoxSizer (see lead photo). The system is a stand-alone e-commerce packaging machine that continuously right-sizes corrugated cases. It does so by slitting their corners and creasing them to create the top-closing flaps after the cases have been filled, just prior to closing and sealing. BoxSizer easily handles random and highly variable footprints and depths of cases.

Upstream of the BoxSizer, a case erector forms multiple and randomly sized corrugated cases, closing and sealing the bottom of each case, but leaving the top open for fulfillment center loading of random, loose product. No scores or slits are made to the top of the corrugated cases by the case erector, so no top flaps yet exist upon entering the BoxSizer.

After filling, the random-footprint corrugated cases are fed into the BoxSizer in whichever order they arrive. Prior to entering, the machine examines each case for overfilling—if product is overfilled, the system automatically engages an overfill reset, which diverts the overfilled box and resets the line.

BoxSizer then measures each case’s outside dimensions and internal void space. It does so using four in-line, drop-down mechanical arms, oriented so one arm addresses each of the four corners of the open, unscored, uncut cases. These arms simultaneously measure the height of the contents within each case, and cut and crease the corrugated at the corners in such a way that they create flaps that close just above highest point of the cases’ contents. After scoring, more mechanical systems fold inner flaps first, then outer flaps are hot melt glued and folded to close the case. Closed boxes are then tape sealed.

It does this dynamically on-demand without stopping for changeover, making it ideal for both B2B and B2C applications, according to the company.

“This process reduces movement of the cases’ contents, takes out the headspace, and reduces the DIM weight of the case,” Chalovich says. “The cases leave the machine perfectly matched to the size of their contents.”

By ensuring optimal DIM weight, the BoxSizer platform can reduce total carbon footprint and improve sustainability. Additionally, right-sized packages keep products secure and neat while making packaging easier to open for end users. To see a video of the BoxSizer in action, go to pwgo.to/5367.

Stock bottles shaped by e-commerce
For Amcor the PACK EXPO Las Vegas show was an opportunity to introduce OmniPack, (3) a new stock bottle offering developed specifically for the co-packer whose role has grown dramatically with the rise of e-commerce. The idea is to transform the definition of stock packaging, specifically, injection stretch blow molded PET packaging for sauces, condiments, or beverages sold through e-commerce. Al Pizzuti, Food Segment Marketing Manager at Amcor, explains some of the thinking behind this intriguing initiative.Photo 3Photo 3

“If you look at the food segment overall, growth is not that impressive. What we’re seeing is that tier two and three players are the ones driving growth, and in many cases they’re doing it by way of e-commerce. It’s no mystery why e-commerce would be so appealing to them, since e-commerce represents a lower barrier to entry, especially when many of these tier two and three firms don’t even need to have their own manufacturing assets because they rely on contract manufacturing/packaging. When it comes to purchasing containers, these firms have to move as fast as possible, and they also have to have something they know will withstand the rigors of the e-commerce channel.

“OmniPack was developed with all this in mind. It’s a range of PET containers in 8-, 12-, 16-, and 20-oz sizes and with continuous-thread neck finishes of 38 mm. Because the containers all have the same footprint, a tier two or three company can add a new size or switch quickly from one size to another without requiring their contract manufacturer/packager to adjust guiderails or other things that involve time and labor. You simply adjust the fill height. This is what these kinds of food companies need.”

The other thing they need if they’re going to sell by way of e-commerce is a package that thay know will function within that channel. Amcor thought of that, too. “Stock packaging in the past meant standard containers designed for retail,” says Pizzuti. “This is different. This is packaging designed specifically for e-commerce, so we put it through that additional level of testing to get it e-commerce ready.”

In other words, these containers are what Amazon refers to as SIOC—Ships In Own Container. Because they’ve been tested and certified, the need for secondary packaging is greatly reduced or even eliminated. For more on how important that is to Amazon, go to pwgo.to/5368.

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