Automated Pack Stations 101

The pack station is where inventory is capitalized by converting inventory to orders in the space between the pick area and the shipping/staging dock(s). By automating repetitive manual tasks, this is done more efficiently and more rapidly. Introducing automation into the warehouse pack station can increase throughput to up to 900-1,200 packages per hour (depending on how much is automated and the size of packages).

1. Document/Sample/Catalog Insertion

PSI’s LC In Feeder can automate material or document insertion at rates of between 10 – 30 per minute, depending on the products.

PSI’s large capacity friction feeder offers packaging solutions for high volumes of media, such as catalogs, to be fed from the inline dispensing system into boxes or totes along the conveyor line. The feeder adds versatility and improves the handling capacity of the automated order fulfillment system.

2. Print on Demand Packing Slips with Folding

Our Print Feeders are able to print packing slips on demand and fold either once or twice before feeding them into passing totes, cartons, or boxes.   The resulting increased packing station efficiency allows for faster order fulfillment and a higher throughput.

3. Carton Close and Sealing

We can integrate any carton closer/sealer that is available in the market into your pack line. Carton sealers can be semi-automatic (involves an operator to push flaps of the carton down and push it through the machine) or fully-automatic. Consistent, reliable carton/case sealing ensures packages arrive intact to your customers.

4. Carton Dimensioning & Weighing

The dimensioning machine collects the necessary information and feeds it into the system to ensure the information is accurate on the shipping label. The check weigher has the ability to weigh the package and verify that all the right products are included inside the package. PSI can integrate into your system any carton dimensioner or check weigher that is available on the market.

5. Shipping Label Printing and Application

Using the customer and package information from upstream tasks, a shipping label is printed and applied to the closed carton as it passes by. This can be done using PSI’s Autoslip or any label printer & applicator on the market.

The Autoslip combines your shipping label/packing slip and return label in one transaction, with up to 10 A4 or Letter size pages. Automating your packing slip insertion will increase your packing station throughput, without adding more packing stations and reduces labor costs associated with fulfillment systems.

Why work with PSI for you Automated Pack Station Needs

We specialize in the last 100 feet of the order fulfillment line to help high volume distribution centres optimize throughput and accuracy while reducing labor costs. PSI Engineering is the technology leader in the manufacture and integration of automated pack and sortation systems, print-on-demand systems, and print-and-apply systems for even the most complex high volume warehouse and distribution environments.

We design, build and integrate fully configured pack station and order fulfillment automation solutions. Our systems ensure increased throughput and accuracy, greater reliability and seamless operation, while reducing labor costs.

Ideally though we provide seamless cradle to grave solutions for clients looking to improve efficient and costs by automating their PackStation area.  When clients want to relieve congestion or bottlenecking in the pack station or have the need to reimplement FTEs in their operation is where we provide the greatest value.  Let us work with you to provide a fully Automated Pack Station leaving you to focus on the rest of your distribution warehouse needs.

We can also provide similar solutions on the induction side of a warehouse by helping with the IB sort or by doing order start if that is an option for our client and their WMS.

Based on your specific needs, we can customize a pack station using any or all of the parts above. In addition, we can accommodate automation of steps including:

  • Carton Erectors
  • Packing slip/return label printing and inserting into an adhesive pouch
  • Reject lines/Hospital lanes
  • Sortation based on parcel destination (check out or Conveyance and Sortation page for more information)

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