Shorter delivery times – including sameday delivery – as well as reductions in delivery charges and minimum order values, have also led to a decrease in the average number of items per order. As the number of items per order falls, more and more space remains unused in the standard shipping boxes typically used.
Oversized parcels pose a major challenge throughout the entire supply chain: from storage, through sorting, transport and distribution, right through to the final delivery point at the recipient’s premises. This results in higher costs due to the space required in warehouses and the need for increased transport capacity on roads and railways.
In the commercial and industrial sectors, too, overnight delivery is increasingly being relied upon for the supply of accessories, spare parts and consumables. The required items must be available from stock and ready for dispatch in the shortest possible time.
| 1 Pack IQ | Kern Production Control makes the packaging line more efficient, transparent, and intelligent: disruptions are detected immediately, while processes and machine performance (OEE) are monitored in real time. Carton consumption and throughput are continuously optimized. The solution integrates seamlessly into existing warehouse, material flow, and enterprise systems (WMS, WCS, and ERP), ensuring maximum transparency and control. |
| 2 Item Feeding and Measurement | Items are placed onto an infeed conveyor and fed into the system. Their dimensions are measured to determine the required packaging size. Depending on requirements, the system can be equipped with multiple feeding stations. |
| 3 Feeding Corrugated Sheets | Packaging is produced from corrugated cardboard sheets. Based on the dimensions of the contents, the System selects the appropriate blank size. Depending on requirements, the system can be equipped with multiple sheet feeders. |
| 4 Processing the Corrugated Board | In the first step, the corrugated board is individually cut, perforated, and creased. The packaging is then erected, glued, and transported to the loading station. |
| 5 Packing the Items | The system automatically transports the items into the custom-sized, preproduced packaging. Before closing, documents such as delivery notes, invoices, flyers, or other inserts can be added. |
| 6 Sealing the Package | After the items are inserted, the package is automatically closed and sealed. Before leaving the system, the parcel is labeled with a shipping label. |
| 7 Logo Printing and Shipping Label | Shipping cartons are addressed and prepared for dispatch. Optionally, promotional or shipping documents can be inserted automatically, and the carton can be customized with individual printing. |
| Operation | 1 Person |
| Package size (internal dimensions) | min. 100 × 150 × 50 mm max. 600 × 400 × 300 mm |
| Package weight | Up to 20 kg |
| Corrugated cardboard sheets | Recommended B-wave 3 mm Feeding from pallet: as continuous web or individual sheets |
| Closure | Hot glue |
| System dimensions | Basic configuration ca. 10 × 16 × 2 m |
| IT Integration | Seamless integration with warehouse and resource management systems (WMS, WCS or ERP systems) |
| The custom-made box meets the key criteria for securely packaging the ordered items: |
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| The packaging is produced on demand, as and when it is needed. |
| The parcel is formed into a self-supporting box, thus offering optimum protection. |
| Logistics and warehousing are significantly simplified. |
| No additional filling material is required. |
| Before the box is sealed, a control photo is taken to ensure the item is dispatched. |
| Optionally, the parcels can be provided with personalised printing or wrapping paper. |
Online trade is booming
The rapid growth of e-commerce is driving increasing demand for paper and corrugated cardboard packaging. Corrugated cardboard is highly valued because it requires minimal storage space when folded, while offering excellent stability and protection for packaged goods despite its relatively low weight. As it is made from recycled paper, corrugated cardboard is also an environmentally responsible choice.
To keep the cost of corrugated boxes low, large quantities of identical boxes must still be produced. Any change in box size results in setup costs during production, as well as time-consuming adjustments to packaging machines. The consequence is a high proportion of empty space that must be transported, stored, and handled unnecessarily. This void is often filled with additional materials such as polystyrene chips or wood wool, leading to inconvenient handling for the recipient.
The clever multi-item packaging
PackOnTime 2box enables the production of corrugated boxes in the optimal size for every individual order. Goods are securely protected during shipping without the need for additional void fill. To produce the right box, the items to be packed are dynamically measured, automatically packed, and the box is sealed. This significantly reduces box volume - making a valuable contribution to environmental protection.
Through integration with in-house warehouse and resource management systems, seamless data flow and error-free order allocation are ensured.
Before the box is sealed, a control photo of the packed contents is taken and linked to the order via the company’s proprietary software. This ensures accurate shipment of all items. Thanks to an integrated tear strip, the box can be opened easily. Its self-supporting structure allows it to be reused for returns or storage if required.
When opened, the packaging conveys a high-quality impression and presents the contents attractively. The boxes can be personalized using pre-printed corrugated sheets or by integrating a digital printing system. The use of corrugated sheets also enables quick and easy switching between different types and qualities.
Our Services
Reliable functionality and support after the purchase. Advice before the purchase, support and assistance after the purchase of a Kern system is the be-all and end-all. Efficient support is one of the most important components of the Kern Group. To ensure optimum system availability and productivity, the Kern Group offers a comprehensive and reliable service programme worldwide.
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