How Repackers Are Slashing Costs and Boosting Output with Automation

Repack operations play a crucial role in the supply chain, especially when it comes to adapting products for retail, club stores, or regional distribution. But many of these facilities still rely heavily on manual labor for processes like unwrapping, bundling, and reboxing. While this may seem flexible and low-cost upfront, the long-term impact on efficiency, labor costs, and worker safety can be significant.

The Hidden Costs of Manual Labor Manual repacking often involves repetitive tasks such as removing shrink film, sorting products, or placing items into new trays or cartons. These tasks are not only time-consuming, but they also carry a high risk of injury due to repetitive motion and sharp tools. Additionally, staffing shortages continue to make it difficult to maintain consistent throughput.

Automation: A Smart Step Forward Forward-thinking repackers are turning to compact, specialized machinery to streamline their operations without a full facility overhaul. Machines like Polypack's Unwrapper offer a targeted solution: safely removing shrink film from corrugated trays in multiple stations. This not only speeds up the process but also reduces waste, labor dependence, and the risk of injury.

Small Footprint, Big Impact Modern automation equipment is designed with repack facilities in mind. Compact machines can be integrated into existing lines with minimal disruption, and their user-friendly controls make it easy for teams to adapt. In fact, many repackers see ROI within months thanks to improved consistency, reduced labor costs, and higher output.

What to Automate First If you're just starting your automation journey, look at processes that are repetitive, labor-intensive, and prone to bottlenecks. Shrink film removal, carton collation, and tray packing are ideal starting points. These are areas where specialized equipment can immediately boost speed and reduce downtime.

A Real-World Advantage Repackers who adopt automation aren't just saving money, they're also winning new business. Faster turnaround times, improved product presentation, and better inventory control give automated operations a competitive edge.

Ready to Learn More? If you're ready to explore automation in your repack facility, start by identifying your most time-consuming manual processes. Machines like the Polypack Unwrapper are specifically built to meet the needs of repackers looking for reliable, space-saving solutions.

Don't let outdated methods hold you back. The right automation can transform your efficiency, reduce your labor costs, and make your line more competitive than ever with automation.

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