Case Studies: How Companies Increased Efficiency Using Solutions from Emmoco

Packaging can either break a company or bring it up, especially since the packages are done at speed, accuracy, and cost control. With the ideal packaging solution, companies have a chance to improve processes, reduce waste, and boost productivity while maintaining costs within a minimum.

We have been involved with a number of businesses at Emmoco; many of them received impressive results through our packaging machines and supplies.

Here, we present a few case studies on real situations showing how Emmoco solutions have been able to help companies operating across diversified business verticals in achieving better packaging efficiency, faster turnaround times, and cost economies. The case studies are as follows.

1. Case Study 1: Operational Efficiency in a Food Distribution Warehouse

Challenge:

A high-volume food distributor from Sydney was facing some delay issues in the packaging of their products. The manual processes were not only time-consuming but very labour intensive, creating bottlenecks on a frequent basis that quite often resulted in not being able to meet strict delivery deadlines. High volumes of goods that day in and day out required processing, needing a solution that would offer smooth packaging without compromise on the safety of the products.

Solution Offered by Emmoco:

After discussing the distributor's needs, Emmoco was able to recommend an automated pallet wrapping system. This not only saved them time in wrapping their pallets but provided a consistent and secure wrap every time, minimising any potential damage to goods while being shipped. We also supplied them with stretch film that had the pre-stretch capability. This enabled them to use less film than before but have strong load containment.

The Result:

More Speed in Packaging: The automated pallet wrapper reduced the wrapping time of every pallet by over 50 percent, which greatly increased daily throughput.
Labour Costs Reduced: With a new system in place, fewer workers were needed to tend the wrapping process, making them more available to other duties throughout the warehouse.
Improved Load Security: Consistent wrapping guaranteed that products would reach destinations without damage. This reduced rate of return and increased customer satisfaction.

Food distributor achieved full return on investment in 18 months with the ongoing savings in time and labour.

2. Case Study 2: Material Cost Reduction for an E-commerce Fulfilment Centre

The Challenge:

A Melbourne-based e-commerce fulfilment centre was plagued by high packaging material costs. As their packing process is manual, there is overuse of tape and stretch wrap; hence, lots of wastage. Inconsistent packing speeds result in delays in peak seasons.

Emmoco's Solution:

Emmoco advocated for automated carton sealers combined with pre-stretch pallet wrappers. These machines are designed to reduce the amount of tape and stretch wrap per package while maintaining the security of the goods. We also introduced a high-performance stretch film which provided maximum coverage using less material.

The Result:

Material Savings - The new packaging machines reduce the tape and stretch wrap usage by at least 30%, hence giving a cut on material costs.
Faster Turnaround: Because of the automation, the centre could take orders significantly faster, especially at times of busy periods without adding additional staff.
Consistent Quality: Every time, the automated case sealers apply a consistent seal sans errors and cuts down reworks.

By reducing the waste and improving efficiency, the fulfilment centre saved thousands of dollars annually in packaging costs.

3. Case Study 3: Scaling Up for a Growing Manufacturing Plant

The Challenge:

The Brisbane manufacturing facility was at a point where an inability to keep pace with increased demand for its range of products was evident. Manual packaging operations constrained production, and the company failed to meet scheduled deliveries as order volumes increased. In addition, heavy packaging loads handled manually were an increasing safety concern - a potential threat to the long-term sustainability of the workforce.

Emmoco's Solution:

Emmoco proposed a completely automatic packing line, complete with carton erectors and pallet wrappers. The carton erectors automatically constructed and taped boxes ready to be filled, while the pallet wrappers ensured large loads were well wrapped and ready for shipment in the least amount of time. This reduced manual handling, which was contributing to slowdowns and putting safety in jeopardy.

The Result:

More Capacity: Because of the automated system, packaging operations for the plant have been scaled up as orders are received, which increased up to 40%, without adding personnel.
Reduced Worker Strain: Heavy lifting and packaging tasks having been automated; the plant reduced its workers' physical stresses; this resulted in fewer injuries and better morale.
Faster Turnaround Times: The plant was enabled to cut its packaging time by half, allowing it to meet growing customer demand and deliver on time, every time.

This investment in automation meant not only growth for the business but also ensured long-term operational sustainability with a safe and efficient manpower resource.

4. Case Study 4: Enhancing Sustainability for a Beverage Producer

The Challenge:

A Perth-based beverage manufacturer wanted to make its packaging operations more viable environmentally. The volumes of plastic wrap used are large, hence contributing a great deal to its overall environmental footprint. At the same time, they couldn't afford to compromise on the integrity of the packaging since beverages need to be well-contained to avoid damage during shipping.

Solution by Emmoco:

We introduced the beverage manufacturer to a number of eco-friendly packaging supplies, including thinner but stronger stretch film that required less material per pallet while maintaining high load containment standards. In addition to this, we recommended a pallet wrapping machine that was energy-efficient and minimised power consumption.

The result of this would be:

Reduced Plastic Use: Thinner stretch film reduced plastic consumption by over 40%, reducing the company's environmental impact considerably with no compromise on packaged quality.
Lower Energy Costs: The energy-efficient machine contributed to their reduction of electricity use in their packaging operations, adding value to their general objectives on sustainability.
Improved Brand Image: With these more sustainable packaging practices, the beverage producer was well placed to communicate their concern for the environment to customers, which was quite well received by them.

The company reached its sustainability targets and was able to reduce costs on materials and energy, thus enhancing its bottom line.

5. Case Study 5: Accuracy of a Pharmaceutical Company's Packaging Process

The Challenge:

Accuracy issues were prevalent within the packaging line of an Adelaide-based pharmaceutical company. Consequently, it was important that the handling of sensitive products could be accurately and error-free packaged. Inaccurate handling-developed manual errors in sealing and labelling-resulted in reworks and delays, raising some serious concerns about non-compliances.

Emmoco's Solution:

To resolve this, we integrated a packaging line complete with automated strapping and carton sealing machines that sealed every package correctly and labelled them with information required without human interference.

The Result:

Zero Defects: Automation did away with the previous manual errors that had resulted in some defects in their packaging; this assured that all packages would be correctly sealed and labelled every time.
Compliance Assurance: Due to proper labelling, the company was easily able to stay within strict regulatory requirements while not having to face fines or recalls.
Smoothened Efficiency: Automation further saved time on every package, and hence they met the production deadlines without any loss of accuracy.

Benefits from automation came sooner for the pharmaceutical company when it saw growth in productivity with a feeling of surety that its products-maintained consistency in packaging. Result-Quality Deliverances from the Emmoco Solution End.

Conclusion

These case studies show that, with the right packaging machines and consumables, businesses can realise very real efficiency improvements, cost savings, and customer satisfaction. At Emmoco, we strive to assist our clients in finding tailored solutions for their own problem-solving, realising new levels of performance.

Whether you're looking to decrease the cost of labour, increase the speed of packaging operations, or make your processes greener, Emmoco has both experience and equipment to make it a success. Contact us today to learn how we can help your business develop better efficiencies and results in packaging.