The picking and packing process can be a costly and complex. Getting it wrong can cause higher costs and slower productivity. Getting it right will support fulfillment growth and long-term efficiency gains.

Risks of Ignoring Inefficient Pack Stations

For many manufacturers and distributors, the pick and pack process has a direct impact on warehouse productivity, business profitability, and the satisfaction of warehouse employees and customers. Without methodically designed packaging stations that meet the demands of both warehouse managers and their packers, companies can experience:

  • Lower productivity and higher labor costs due to unhappy packers
  • Dissatisfied customers due to longer production lead times and slower order throughput
  • More risk of worker injury due to non-ergonomic pack stations
  • Higher packaging material costs due to inefficient and disparate packing methods
  • Poor demand forecasting due to process unpredictability

Packer Challenges

  • Pickers are paid to walk an average of 15 miles per day, which equals more than 50 percent of time spent on the job
  • 90 percent of labor in a packaging operation is non-value add, with efficiency rarely above 60 percent
  • A packer on the job for one year is 10 percent more efficient than a new employee
  • Packers risk daily strain and injury when repetitive actions in the packing environments do not fit the needs of the operator

Packer Challenges

Solutions to Optimize Pack Stations for Long-Term Success

Eighty-five percent of the total cost to deliver a package is spent in labor, freight, and damage. By automating some pack station processes, you can support growth by reducing costs and increase pack station productivity tenfold. Sealed Air pack station solutions easily integrate into existing fulfillment environments with minimal financial investment.

Sealed Air Jiffylite Auto

Jiffylite® Auto

Semi-automated cushioned mailer system that enables small-parcel shippers to improve throughput velocity and reduce freight costs.

Sealed Air Products UK - Stealthwrap One Step

StealthWrap™ One Step

StealthWrap™ One Step is a small footprint shrink wrap system, ideal for low-volume shippers, which reduces package dimensions and associated freight costs.

 FasFil 1500

FasFil® 1500

High-performance paper void fill machine that keeps pace with dynamic fulfillment demands and is 100 percent curbside recyclable.

NewAir I.B.® Nano

NewAir I.B.® Nano

On-demand inflatable cushioning and void-fill system which reduces freight costs, warehouse space and inventory management.



See how we solve complex fulfillment challenges

See how we solve complex fulfillment challenges

 Complex Fulfillment