Boost Efficiencies While Lowering Labor Costs with End-of-Line Automation

Historically, when distribution operations sought to gain productivity and efficiencies, their first focus was on order fulfillment and picking, as automated and operational design additions could impact these highly manual processes. As technologies have become more advanced and mature, automating the end-of-line packaging process has become an increasingly popular automation point. Organizations can realize a faster return on investment (ROI) through savings in material and shipping costs as well as gains in accuracy, productivity and throughput.

In 2015, FedEx and UPS adopted the dimensional weight (DIM) pricing guidelines, changing how distribution networks shipped orders. Instead of charging based on the weight of a box, they now charge based on a box’s weight and dimensions, effectively charging for the amount of space a package occupies in the delivery truck.

In 2025, a new wave of regulations began to pick up steam to entice organizations to further reduce waste and adhere to stricter shipping policies. The European Packaging and Packaging Waste Regulation (PPWR) will replace the current packaging reduction directive in 2030 . The PPWR will require that grouped, transport and eCommerce packaging have a maximum “empty space” ratio of 50% in each shipped package. The directive will consider packing material, filler and protective wrap as empty space.

While North America currently lacks federal regulations similar to PPWR, several states, including California, Massachusetts and New Jersey, are considering regulations aimed at limiting plastic and waste and promoting recycling efforts. End-of-line packaging automation can help with compliance and future regulatory issues while significantly reducing labor, waste and shipping costs.

Cut costs while boosting productivity, efficiencies and sustainability

Packaging automation transforms warehouse operations by reducing labor costs and reallocating workers to more essential tasks. It also increases efficiency, cuts material costs and provides a mature and sustainable solution for your organization. Below are some of the immediate benefits of packaging automation.

Labor cost reduction: Employing packaging automation can dramatically shift how an organization addresses its labor use and dependencies. By eliminating traditional packing stations, an operation can divert workers to other labor-intensive processes in the warehouse while reducing the need for temporary, seasonal and peak hires.

Gains in efficiency: By automating the final step in the warehouse fulfillment process, an operation can reduce order fulfillment time while reducing typical bottlenecks associated with manual packing. This allows for optimized product flow and productivity.

Material cost savings: By right-sizing an envelope or box to fit the item(s), an organization can significantly reduce the materials needed to ship each order. Package, filler and bubble wrap material can be substantially reduced or even eliminated.

Increased throughput: Packaging automation can automate the process of wrapping an order, sealing an envelope or box, and affixing a mailing label on one line. This allows an operation to automate highly manual processes and increase throughput and shipping accuracy.

On-demand printing: Right-sizing a package per order offers an operation the opportunity for on-demand printing. This can deliver marketing benefits by printing a company’s logo or customer messaging on the package before it is wrapped and shipped.

Sustainability: One of the most significant advantages of an end-of-line packaging automation solution is its commitment to sustainability and eco-friendly processes. Right-sized boxes and envelopes use fewer materials and can be created from recycled materials. This can help operations remove poly from their outbound processes while meeting customer demand and delivering high-quality packaging.

FORTNA Can Help

By integrating end-of-line packaging automation, organizations can significantly reduce their dependency on labor, enhance efficiency and control costs. An end-of-line automation solution aligns with evolving regulations and prepares operations for future sustainability mandates. FORTNA can guide you to an automated and efficient supply chain network, ensuring you remain competitive and compliant in a rapidly changing market.