On-demand packaging brings precision to ecommerce fulfilment
The growth of direct-to-consumer retail is changing packaging from a routine warehouse task into a measurable operational cost. Instead of replenishing stores with standardised bulk shipments, fulfilment centres must process large numbers of individual orders, often containing different products and quantities.
In the UK, online retail accounted for 27.4% of consumer spending during 2025 and reached 29.9% in the final quarter, according to the ONS Retail Sales Index. Ofcom’s 2025 Annual Parcel Report recorded 4.2 billion parcels sent and received by UK consumers in 2024. Those volumes are increasing pressure on picking, packing and dispatch processes.
Boxes made for the order
Fixed box ranges can leave substantial unused space, while manual packing requires labour and can consume large amounts of void fill. Automated right-size systems address both issues by measuring an order and producing a corrugated box matched to its dimensions.
Packsize supplies semi-automated and fully automated equipment for this approach. Its systems can produce formed and sealed boxes at rates of up to 1,300 packages per hour, supporting operations ranging from lower-volume sites with varied products to high-throughput ecommerce facilities.
The company reports average reductions of about 30% in corrugated material use, package-volume reductions of up to 40% and around 80% less void fill. It also says a fully automated line can provide output comparable to approximately 20 manual packing stations, although results depend on the products and existing process.
Connecting packaging with fulfilment
Right-size technology can be deployed in box-first or box-last configurations. A tray may be created before picking and closed after the items are placed inside, removing the need for plastic pick totes. Systems can also switch between operating modes during production.
Smaller cartons can increase vehicle utilisation and may reduce the number of journeys, fuel consumption and associated emissions. Packsize supports both new warehouse developments and integration into existing facilities, with connectivity to warehouse management systems intended to make packaging part of the wider material flow rather than an isolated end-of-line activity.
