Packsize expands automated right-sized packaging portfolio
Packaging automation is moving beyond high-speed box forming. By producing corrugated cartons to the dimensions of each order, right-sizing systems are targeting three persistent fulfilment challenges: wasted material, excessive transport volume and labour-intensive packing decisions.
Packsize has built its business around this model since 2002. Its machines cut and fold corrugated board on demand, creating a carton matched to the contents rather than forcing products into a limited range of standard boxes. The company has established operations in Europe and recently moved its European headquarters to Amsterdam.
Automation linked to warehouse data
The technology can operate in box-first or box-last configurations. In the first approach, the carton is made before packing; in the second, products are conveyed into the system and the packaging is formed around them. Both options can be supplied as semi-automated or fully automated installations.
Dimensions may be taken from a warehouse management system or calculated from inducted products. This reduces the need for operators to select cartons manually and makes packaging part of the wider material-flow design. Packsize says fully automated installations can deliver output comparable to about 20 manual packing stations, although actual performance depends on the product mix, order profile and existing process.
Reported customer averages include roughly 30% lower corrugated consumption, package-volume reductions of up to 40% and around 80% less void fill. Smaller parcels can also increase trailer utilisation and reduce the number of vehicle movements required for a given shipping volume.
Growth through broader technology coverage
The acquisition of Sparck Technologies in 2025 and the planned purchase of Panotec’s packaging business in Italy are intended to extend Packsize’s capabilities across three-dimensional right-sizing. The company serves small and large operators, including fulfilment businesses with multiple brands and product categories.
Digital printing adds another layer of flexibility. A machine can produce cartons in different sizes with individual graphics, enabling branded unboxing or additional advertising space. Packsize reports that one SME processing about 1,200 parcels daily redistributed eight employees after installation and expects a two-year return on investment; typical payback, according to the company, is two to five years.
The systems can be integrated into existing warehouses or considered from the outset of a new facility. For industrial companies, the implication is that packaging is becoming a measurable automation layer rather than a final manual step.
More information is available from Packsize.
