Baggingto Budget

The Newsletter of Automated Packaging Systems Issue 17

www.autobag.co.uk

Mail Order Fulfilment Special

What will you bag with your FAS SPrint Revolution?

Protective packaging at the push of a button

Cutting the cost of handbagging

Technical advances herald faster medical device bagging

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ContentsCalculating returns on investmentAutomated Packaging Systems has more than 30,000 bagging systems in operation around the world, bagging anything from washers to wing mirrors and syringes to sausages. Whatever they bag, our customers benefit from superb service and a wide range of bag features, materials and print options.They choose Autobag, SidePouch and AirPouch for three simple reasons:

Cost: our systems bag up to 10x faster than the most experienced hand-bagger, cutting the cost of bagging by up to two-thirds.

Flexibility: changing bag size on an Autobag AB 180 can take less than 2 minutes

Reliability: our brands are renowned for reliability; when customers’ repeat purchase – which they do, a lot – they tell us it’s reliability and service that keeps them loyal.

Our customers bag more than just their products; they bag improvements in efficiency, brand value and profitability. What will you bag?

Copyright Automated Packaging Systems, Autobag®, AirPouch™ & SidePouch™ are all registered trademarks of Automated Packaging Systems. No reproduction without prior concent is permitted.

Designed & Printed by b1 Group Phone: 01527 557 050 Email: more@b1group.co.uk

Written by Whisper.pr

Bagging to Budget2012 Edition 17

Systems for MailOrder applicationsPage 4

Pick and Pack baggingPage 6

NEW AirPouchUltra Light filmPage 9

Protective packagingat the push of a buttonPage 11

Faster medical devicebaggingPage 15

Pet food packer doublesoutput to meet demandPage 18

Hands-free desktop bagging Page 19

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M Mail Order Specials

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The economic outlook in 2012 remains unpredictable, to say the least. Automated Packaging Systems, like other long-standing companies, has weathered many storms since it was founded in 1962. Our ability to remain on a firm financial footing, even in the darkest hours of recession, is largely thanks to the loyal partnerships we have developed with our customers.

As we draw close to our 50th anniversary, it’s an appropriate time to say “thank you” to all our stakeholders – customers, suppliers and employees.But what does being in business for 50 years really mean? For me, it’s an opportunity to reflect on the lessons learned and the experienced gained from all those years of successful operation. Lessons such as:

• Understanding the importance of delivering a well-made product at the time it’s required.

• Providing the technical support and in-house expertise to ensure the benefits of using our products are enjoyed seamlessly by every customer.

• Maintaining the pace of innovation, so that our offer remains fresh and inspirational.

• Investing in state-of-the-art manufacturing equipment and techniques, to ensure a culture of continuous improvement.

Our challenge at Automated Packaging Systems is to apply the lessons learned over the past 50 years to the mutual benefit of both our company and our customers. This loyal partnership has done us proud since our humble beginnings in 1962. I would like to see it continue for at least the next 50 years.

by Peter Wylie

Managing Director of Automated Packaging Systems Europe

Welcome

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MAIL ORDERSPECIAL

Systems for mail order applications

The proven value, reliability and flexibility of our systems isn't just limited to apparel and non-breakable goods. Our AirPouch Express 3 pillow system and the bubblewrap-on-demand AirPouch FastWrap provide void-fill and protective packaging for breakable goods and for those delivering in boxes and cartons.

For technical specifications and details of the full range of Autobag and SidePouch mail order fulfilment systems and AirPouch protective packaging solutions log on to www.autobag.co.uk and www.airpouch.co.uk or call Automated Packaging Systems customer service on 0800 731 3643.

Typical Applications

• Clothing• Shoes• Consumer electronics and accessories• Pharmaceutical distribution• Printed materials

Standard Features

• Easily intergrated into fully automated warehouse systems• Box-like bag opening for easy insertion• Three point scanning verification to ensure accuracy• Automatic printing and labelling system• Easily accommodated products racks, carts and conveyors• Remote diagnostic capabilities

Autofulfillment SPrint

Our Mail Order Special spotlights the latest mail order fulfilment solutions from Automated Packaging Systems - The Autofulfillment SPrint that slips into traditional packing lines to boost efficiency, and the Autobag OneStep systems which improve the performance of individual packaging stations, bagging up to 10x faster than the fastest hand bagger. Both deliver faster, more efficient and more flexible bagging for apparel, electronics and non-breakables.

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MAIL ORDERSPECIAL

Typical Applications

• Mail order fulfilment • Catalogue order fulfilment • Spare parts distribution • Short-run production with frequent changeovers in any market

Standard Features

• AutoTouchTM Control Screen• On-board memory and PI 412c remote keypad• Standard Footswitch to cycle bagger• Product Load Shelf to support heavier products• Powered Unwind System

AB 180 OneStep PS 125 OneStep

Typical Applications

• Mail order fulfilment• Automotive and appliance parts• Hardware and electronic• Cosmetics and beauty aids

Standard Features

• Small footprint, 550mm x 480mm frees up valuable tabletop space• Operator friendly control panel• Menu stores up to 10 jobs in memory for rapid recall• Auto-Thread™ feature for easy bag changeovers

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Pick and fast-Pack“Automated and semi-automated bagging systems can substantially increase the efficiency of UK mail order fulfilment operations.”

That’s the claim made by Automated Packaging Systems mail order expert Martin Richards, and it’s based on worldwide performance data on the businesses OneStep™ and Autofulfillment™ SPrint™ systems.

“Recent innovations in Pick and Pack technology have been focussed on the pick side of the operation,” explains Martin Richards. “But with developments in our bagging systems there’s evidence that customer packing lines can operate up to 12 times faster than they were achieving with even their most experienced hand baggers, allowing them to switch labour to picking operations to increase overall productivity.”

The new SidePouch Autofulfillment SPrint seamlessly fits into an automated packing line. Its input conveyor brings product to one of five pre-opened mail bags then packs, prints and affixes address details to the bag, producing and inserting a packing slip or invoice before sealing and passing to dispatch on an output conveyor. A 3-point scanning verification system checks every step.

MAIL ORDERSPECIAL

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“Autofulfillment SPrint is a more flexible, reliable conveyor-fed alternative to the more traditional automated mail order fulfilment pack stations,” explains Martin Richards. “It’s been designed for high volume fulfilment applications and can be customised for a wide range of products from apparel and footwear to consumer electronics, homewares and healthcare or hardware and spares – in fact, just about anything that will ship in a poly bag.

“Unlike the alternatives, Autofulfillment SPrint bags can be changed in minutes by the operator, reducing downtime and the need for engineering support. There’s a wide range of bag materials on offer including standard UV-protective film mailbags with white outers and black inners. All bags can be branded with high quality print, easy-openers and reseal options are available for any business focussing on improving the customer experience and perception of value.

“Our OneStep systems, on the other hand, require less capital investment per unit, making them ideal for applications where goods are packed in several areas within a facility, or where customers wish to share the workload across multiple systems.”

The OneStep systems do exactly that: print postal and traceability data on the next bag out, then open it for packing and sealing in a single ‘step’. The AB OneStep systems are part of the ultra-reliable Autobag range of baggers and are available in vertical and horizontal configuration, processing bag sizes up to 400mm x 700mm. The entry-level AB OneStep has a footprint as small as 1m x 1.4m, thereby offering a high productivity packing line with minimal space requirements, for

warehousing operations where floorspace is at a premium. For smaller products and lower volumes, there’s even a plug-and-play desktop-based PS 125 OneStep which is still capable of packing up to 10 times faster than the most experienced hand bagger.

While the AB OneStep systems can be successfully integrated into a traditional automated packing line, their great advantage is their performance when used as a semi-automated packaging solution. An AB 255 OneStep, for example, makes it possible for a single packer to increase output 10-fold without the need for substantial capital investment and system restructuring.

Martin Richards explains: “Because the OneStep systems print and index in a single operation, operators can achieve typical process rates of between 360 and 600 packs per hour. The in-built AutoTouch™ control screen makes it quick and easy to set jobs up, and there are a range of software options to link order, pick, pack, dispatch, mail and courier systems.

Martin Richards specialises in Automated Packaging Systems mail order fulfilment applications. To find out more about Autofulfillment SPrint and the Autobag OneStep systems email him at martin.richards@autobag.co.uk or call customer services on 0800 731 364

Martin Richards

MAIL ORDERSPECIAL

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Typical Applications

• Mail order fulfilment • Third party logistics • Electronic supply • Contract packaging/fulfilment• Automotive • Pharmaceutical • Office supply

Standard Features

• AirPouch cushions have EZ-Tear perforation for easy separation and handling • Reliable equipment requires minimal maintenance • Minimal downtime with up to 45% more material per box • Simple adjustment with air volume and length timer • Available in a range of cushion sizes including 100mm x 200mm and 200mm x 200mm• Knifeless system

AirPouch Express 3The AirPouch Express 3 tabletop void-fill system provides easy to use air pillows on-demand for fast, easy packing ideal for void-fill applications.

MAIL ORDERSPECIAL

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The new Ultra Light gauge film is available in the company’s innovative EarthAware film produced from single-source reprocessed material, standard polyethylene as well as in oxo degradable form. According to Automated Packaging Systems AirPouch expert Colin Gunnell, customers can be confident that both options offer the highest standards of performance.

“Air Pillow integrity and performance are primarily products of seal quality and consistency of air flow – both functions of the filling system. AirPouch Express 3 is designed to produce smooth high quality seals which perform well under pressure and over time.”

All AirPouch films for European use are converted and formed into pillows at the company’s production facility

in Malvern, Worcestershire, which were extended in 2010 to meet increasing demand. “Our new Ultra Light pillows are the first in a long line of innovations which are being made possible as a result of our newly extended facilities. We’re also responding to increases in demand for branded void fill pillows which makes great use of expertise we’ve developed on the branded bag side of our operations.”

AirPouch Express 3 is now available with Heavy Gauge, Light Gauge and Ultra Light Gauge pillows formed from standard polyethylene and oxo-degradable film. Light and Heavy Gauge pillows are also available in EarthAware™ material - the company’s highly acclaimed reprocessed film.

NEW AirPouch Ultra Light film gives it a competitive edge Automated Packaging Systems has unveiled a new Ultra Light gauge film for its AirPouch Express 3 system, adding to an already extensive range of air pillows and potentially cutting the environmental impact and cost of void-fill and protective packaging.

MAIL ORDERSPECIAL

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Typical Applications

• Electrical components• Automotive aftermarket• Cosmetics and health & beauty• Hobby & craft products• Glass & giftware• Pharmaceutical and medical supplies

Standard Features

• All electric design, does not require compressed air• Easy of use for operators, simple controls• Reliable equipment, minimal maintenance requirement• Compact design, small footprint• Fast operation, up to 19 metres per minute

AirPouch FastWrapThe AirPouch FastWrap system produces filled bubble or tube quilts used for protective packaging, such as wrapping, interleaving, and block and brace applications.

MAIL ORDERSPECIAL

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Fielding and Chavannes invented bubble wrap back in 1957 - they were trying to invent removable wallpaper by bonding two shower curtains together. It didn’t take long to see the protective properties of their creation, and it was soon being used to wrap IBM computers.

Berney and Hershey Lerner’s latest contribution to the protection of shipped products is more recent and greener. The founders of Automated Packaging Systems – which celebrates its 50th anniversary this year - created FastWrap to deliver bubble wrap at the touch of a button.FastWrap is a plug-and-play tabletop system; the all-electric design is easy to set-up, simple to operate and doesn’t require compressed air. The bubble sheet is perforated so the system has almost no wear parts; there’s no blunt knife replace.

It’s fed from a high-yield box and at speeds of up to 19 metres per minute – one carton of FastWrap generates almost half a kilometre of protective packaging.

“The FastWrap machine is designed for consistently reliable performance,” explains Colin Gunnell of Automated Packaging Systems. “The system is easy to use, needs minimal maintenance and features technology that’s unlike any other on-demand protective packing system in its class.”

To find out more visit www.airpouch.co.uk or call Automated Packaging Systems void-fill and protective packaging expert Colin Gunnell on 07976 833784.

Protective packaging at the push of a button

What do Fielding and Chavannes and Berney and Hershey Lerner have in common? No idea? They are all responsible for advances in protective packaging...

MAIL ORDERSPECIAL

AB 180Capable of bagging at speeds up to 80 bags per minute, this semi-automatic filling and sealing machine has been designed to be simple and easy to use.

Typical Applications• Automotive & appliance parts

• Hardware & DIY

• Electrical & electronic

• Fasteners & connectors

• Plumbing & heating

• Hobby & craft

• Jewellery & novelty items

• Cosmetics & beauty aids

• Disposable health care

Standard Features• Colour AutoTouchTM control screen interface: - 250mm screen, offers operator

tutorials, data storage, help system and diagnostics - Performance monitoring e.g. production rates per job, bags-per-minute/hour, etc.

• Powered Unwind System for positive bag-web control ensures minimum bag movement for accurate positioning and loading and for in-line printing accuracy

• On-board memory stores job data ready for recall at a later time

• AutoThreadTM automatic bag threading for quick and easy set-up and changeover

• System handshaking using AutoLinkTM ports allows tie-in to Autobag in-feeds and a wide array of third party equipment

• Simple mechanical height adjustment for added operator comfort

• Multiple language choice—English, Spanish, French, Dutch and German available by making a selection on the touch screen

• Product Load Shelf to support heavy product applications and Bag Deflator for air evacuation prior to sealing

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It’s quick and easy to get a system in place and requires relatively little capital investment and outlay. The challenge, however, is to recognise when the time has come to automate; identifying when handbagging has become a barrier to business growth and profitability. “My customers often find that the strict terms of business offered by retailers mean that their own production and packaging operations need to be almost infinitely flexible,” explains Automated Packaging Systems’ Paul Jauncey. “That can be a huge issue if you’re relying on labour-hungry hand-bagging or using packing systems with long set-up and clear-down procedures.

“Because an Autobag AB 180 packs up to ten times faster than

an operator can do by hand, there’s significantly more scope to increase capacity, enabling you can vary production output to meet the needs of the market. In turn that means you can make the most of every sales opportunity to grow your business, and you can do it without sacrificing flexibility.”

For example, one Midlands business will save more than £70k this year thanks to Automated Packaging Systems. They’ve sliced two thirds off their packaging bill and retained the flexibility to bag short runs of different sizes of product – they can change bag sizes on their new Autobag AB 180 in less than 2 minutes.

Labour represents the biggest saving – AB 180 bags up to 10 times faster than the most experienced hand-bagger. Installation and maintenance is dealt with thanks to a comprehensive support packaging, and training is hassle-free; Autobag

systems are renowned for simplicity and reliable.

“Taking into account the capital cost, bags-on-a-roll and operating labour requirements,” calculates Paul Jauncey, “they’ll see a return on their investment in less than 14 months.

“They bag consumables on their Autobag AB 180. What will you bag?”

Cutting the cost of handbaggingHandbagging is often the simplest packaging choice for many small business and start-ups.

Paul Jauncey

AB 180 HD-EThe HD-E system is specially designed for optimum performance in applications where thicker, tougher and stiffer films are required.

Typical Applications• Medical paper

• Single use medical devices

• Sterilisable medical

• Seal validation

• Heavy gauge materials

• Complex film requirements

Standard Features• Colour AutoTouch™ control screen

interface: 250mm screen, offers operator tutorials, data storage, help system and diagnostics - Performance monitoring e.g. production rates per job, bags-per-minute/hour, etc

• Powered Unwind System for positive bag-web control ensures minimum bag movement for accurate positioning and loading and for in-line printing accuracy

• On-board memory stores job data ready for recall at a later time

• AutoThread™ automatic bag threading for quick and easy set-up and changeover

• Simple mechanical height adjustment for added operator comfort

• System handshaking using AutoLink™ ports allows tie-in to in-feeds and a wide array of third party equipment

• Multiple language choice English, Spanish, French, Dutch and German available by making a selection on the touch screen

• Finger switches for ease of operation

• Product Load Shelf to support heavy product applications and Bag Deflator for air evacuation prior to sealing

• Max Pack Weight 2.27kg

• Validatable Temperature, max tem 204oC/400oF

• Bagger & printer tolerances +/- 1.5mm

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Medical device manufacturers stand to benefit most from the developments – the HD-E flexible bagging system packs with medical paper pouches for terminal sterilisation up to 6-times faster than even the most experienced hand bagger.

System manufacturer Automated Packaging Systems created the HD-E for applications that demand flexibility – bag changes, for example, can be completed in just a couple of minutes – but that also require thicker, tougher and stiffer films.

Its engineers built on field-proven technology and an unbeatable reputation for reliability, adding components that improve bag indexing, opening and sealing.

For example, increasing the airflow during the automatic bag opening phase has increased the loading area, making it easier and quicker to fill each bag. And when it comes to sealing, the new cartridge heater provides accurate and consistent temperature control, making it possible to achieve a validatable seal on tougher, thicker materials including medical paper pouches.

ROI data from comparable applications which assess Autobag systems against the traditional alternative – handbagging - show increases in productivity of up to 60% can be achieved with fewer than half the staff, delivering savings of up to 35% on total packing costs.

The HD-E uses system-matched pouches made up of a base web

medical paper and a top web PET/PE. The top web of Peelclean EO-R, a pure wet strength clean-peelable medical grade paper, has excellent barrier properties and superb handling and sealing qualities.

In combination, the medical paper and PET/PE provide excellent sterilisable properties in a quality, brandable, printable pouch ready for overprinting with 2D & 3D barcodes, graphics, product details and instructions.

For more details about the Autobag HD-E bagger for medical applications, and for details of the full range of bagging and void-fill systems from Automated Packaging Systems, visit www.autobag.co.uk.

Technical advances herald faster medical device baggingEngineering advances in bag indexing, opening and sealing give the NEW Autobag HD-E bagger greater strength and power, enabling it to achieve validatable seals on tougher, thicker packing materials.

FAS SPrint RevolutionThe FAS SPrint Revolution Bagging System brings new levels of speed and versatility to demanding packaging environments that require daily washdown procedures.

Typical Applications• Frozen foods

• IQF food products

• Meat, poultry, fish and meat by products

• Fresh produce, fruits and vegetables

• Fresh and dried pastas

• Fresh and frozen snack foods

• Pet food products

Standard Features

• Adjustable 1.5 m load area accommodates multiple infeed configurations

• Coordinated Motion Seal Flattener and band sealer produce consistent, high quality seals

• AutoTouch™ Control Software enables easy access to job set-up and storage with advanced user access to system diagnostics

• On-board memory stores data for up to 25 jobs for easy recall

• Integrated Allen-Bradley control package for reliability

• IP56 enclosures ensure safe operation in washdown environments

• Entire system mounted on casters for mobility

• AutoThread™ feature simplifies and speeds bag changeovers

• Footswitch for manual bag indexing

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They list reliability, flexibility and quality among their top reasons for switching – as well as SPrint’s corrosion-resistant, stainless steel construction which was designed for convenient washdown procedures - but there’s no doubt that the low capital outlay requirements and substantial savings in bagged unit costs are making the decision easier.

Actual ROI data for one packing operation details a 60% increase in production with 50% less labour. The company manufacturers and packs frozen burgers for the catering trade, servicing a wide geographic area. It bags in clear polyethylene bags which are then packed in cartons for shipping.

It looked at several different automated bag packaging systems before choosing FAS SPrint Revolution - its speed, 6-inch pass-through, and packer-friendly ergonomic design were the deciding factors. The SidePouch™ system delivers pre-opened bags along a horizontal track that is directly in front of the packer. A conveyor brings stacks of burgers to the packing station where they are manually inserted into the bags, and as each bag is filled, it continues along a track to be band-sealed, picked-up and boxed for dispatch.

Before the FAS SPrint Revolution was commissioned, the burgers were packed by four handbaggers. Now just two operators oversee bagging, and between them they bag up to

1500lbs more burgers in an 8-hour shift. It’s a lot of meat... the FAS SPrint Revolution outputs over 6400 bags per shift; a weighty 32,000lbs of beefburger. Each bag contains five pounds of burgers of varying sizes including 10 half-pounders and 20 quarterpounders.

Automated Packaging Systems engineers designed the stainless steel food bagging system for easy cleaning, harsh environments and daily washdown procedures. Its operator-friendly design means up to three packers can work side-by-side for maximum productivity. And for maximum efficiency SidePouch bags can be changed by a single operator in less than two minutes; they come fan-folded in a carton that holds up to 4000 bags.

What will you bagwith your FAS SPrint RevolutionUS meat packers are turning to FAS SPrint Revolution to bag anything from burgers and chicken portions to bakery products and veg, much of which is destined for the freezer aisle and almost all of its packed in high-value branded PE bags.

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Typical Applications

• Automotive & appliance parts• Hardware & electrical• Hobby & craft• Cosmetics & beauty aids

Standard Features

• Available with or without printer• Small footprint, 550mm x 480mm, frees up valuable tabletop space• Stores up to 10 jobs in memory for rapid recall• Automatic bag sealing and indexing• Multiple ports: USB, Serial, Parallel and Ethernet

PS 125The PS 125 Tabletop Baggers are specifically designed to bring simplicity, versatility, quality and value to hand load packaging applications.

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The subsequent increase in output highlights just how big an impact unreliability and inefficiency have on business growth.

Prior to the upgrade output their output of reptile and amphibian feed was being limited to around 400,000 units a year, in part as a result of regular breakdowns. But with the addition of an Autobag PS 125 desktop bagger capacity has more than doubled, reaching 900,000 bags without the need for additional labour.

Quick bag changeover, unbeatable reliability and pressure on space in the packing zone are the main reasons behind the PS125 purchase. The Autobag system’s low capital investment requirement also made it easy to demonstrate the business case.

Did you know that PS 125 can be configured for fingertip or hands-free operation, letting toes do the close while hands focus on filling?

Unlike some desktop bagging systems, PS 125 can be configured with Push-to-Seal technology for users who want all the control at their fingertips, or with a standard footswitch.

Whichever you choose, both modes deliver substantial improvements in productivity over hand bagging. A PS 125 OneStep™, for example, can bag up to six times faster than the most experienced handbagger, and because there’s no cardboard header, staples or labels involved, the packaging is recyclable, improving the green credentials of your products in an increasingly environmentally aware world.

Let your toes do the close

Pet food packer doubles output to meet demandIncreasing demand for natural pet food and reliability issues with non-Autobag equipment have forced one Home Counties-based distributor to upgrade its packaging operation.

Find out more at www.autobag.co.uk or call 0800 731 3643.

ResMed, the Australian-based respiratory disorder products specialists, has recognised the excellent products and services from Automated Packaging Systems with a coveted 2011 Top Supplier Award.

It’s a highly prestigious honour for Automated Packaging Systems which has begun celebrations of its 50th Anniversary in 2012 by restating its core commitment to exceptional quality and service. The award is based on measurable performance data in areas of product quality, service performance, documentation and on-time delivery. Only a very small number of suppliers make the grade, providing ResMed with exceptional service at its manufacturing operations in Sydney Australia, Duncan South Carolina, Singapore, and in Europe.

“We are proud to support our global customers with world-class products and services, no matter where their operations are, and we are honored to achieve Preferred Supplier Status from ResMed,” says Cliff Brehm, President and Chief Operating Officer, Automated Packaging Systems. “The partnership with ResMed works well because they clearly communicate their global objectives, which enables us to provide international logistics and service capabilities to meet their needs.”

RedMed’s Supplier Performance Evaluation Committee uses a grading system to evaluate the performance of all tier one suppliers on a scale from 0 to 100%. Automated Packaging scored above 90% for two consecutive 6-month periods to achieve a rating which “exceeds expectations.”

Our range of Autobag equipment provides flexibility and efficiency to a range of industries where customers are improving their productivity. Whether stepping up from hand bagging or integrating into fully automated lines, we have an Autobag solution that will exceed your requirements

High capacity hand packaging or automatic infeeding. SidePouch offers packaging versatility and flexibility for a wide range of industry sectors.

UNITED KINGDOM Automated Packaging Systems Ltd., Enigma Business Park, Sandy’s Road, Malvern, Worcestershire, WR14 1JJ Tel: +44 (0) 1684 891 400 Fax: +44 (0) 1684 891 401 Email: mktonline@autobag.co.uk www.autobag.co.uk UNITED STATES Tel: +1-800-527-0733 www.autobag.com FRANCE Tél: +33.4.72.15.86.50 www.autobag.fr DEUTSCHLAND Tel: +49 531 263050 www.autobag.de BELGIQUE, NEDERLAND & LUXEMBOURG Tél: +32 2.725.31.00 www.autobag.be POLSKA Tel: +48 66 4985916 www.autobag.pl

The protective packaging solution that reduces your transport costs while ensuring that products are transported securely. Whether your requirement is void-fill, wrapping, protection or block and brace our solutions are efficient and cost effective.

International accoladeCliff Brehm