The perfect fit for bulk packers

Sep 06, 2025 Warehousing Ireland Materials Handling, News, Storage, Warehousing Comments Off on The perfect fit for bulk packers

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Bulk packers stand to reap the full benefits of highly flexible, automated fit-to-size boxing technology by being able to flip from runs of thousands of identical boxes to a variety of individually sized packages, using different flute types, all on the fly. By Jo Bradley, Business Development Manager at Sparck Technologies

A growing number of forward-thinking businesses in e-commerce and other fields are enjoying the economy, productivity, flexibility and sustainability of ‘right-size’ automated packing lines, whereby every consignment, be it a single item or an assortment of goods, is given a bespoke box of just the right size to hold the goods without unnecessary voids and the need for void fill. But one sector in particular stands to benefit the most from this advanced, highly-flexible technology.

While for many packers and shippers, each consignment is effectively a one-off, there are others who, while they face the same challenge of needing an almost infinite variety of box sizes and proportions, nonetheless have the requirement for relatively large runs of identical packages. These businesses in the bulk packaging sector may be packing batches of identical consumer products, kits, automotive/engineering parts or a variety of wholesale electrical goods. Such a variety of goods in a wide range of sizes would ordinarily require a huge stock of boxes in a vast array of sizes and flute weights – a nightmare for any organisation. And of course, an army of skilled manual packers would also be needed to do the packing.

But with the latest automated right-size boxing systems from Sparck Technologies, flexibility is virtually limitless. Sparck’s packaging systems have the capability to tailor-make up to 1,100 packages per hour, for multiple or single item orders, with perfectly sized boxes created time and time again from a choice of feedstocks – providing consistency and precision for easy palletising.

Just one smart, flexible machine  

One machine can produce thousands of identical boxes, perfect for bulk shipping, but just as easily can flex to an almost limitless sliding scale of sizes on demand – even switching on the fly between standard B-flute and the much stronger double wall corrugate.

This is great news for bulk/batch packers and shippers. They can enjoy all the benefits of using a single, or just a very few specifications of feedstock, without the need to carry a huge inventory of differing box sizes, saving on storage space, cash tied up in rarely-used box sizes, and on change-over times. Also, it saves on having to maintain different packing lines for different box sizes.

The wider advantages of ‘fit-to-size’ automation are clear. One Sparck CVP line with one or two operators can replace up to 20 manual packing stations, with the CVP Everest machines making up to 1,100 boxes an hour. Even the best manual packer struggles to achieve better than 30-40 an hour, often less for a complex mix of items.

Flexing for peak 

Sparck’s CVP ‘right-size’ automated boxing solutions reduce or eliminate errors, bottlenecks and line interruptions, and are highly scaleable to accommodate peaks in demand. The economics are very favourable even if the line is normally operating well below rated capacity. And its intrinsic flexibility means that it can jump-in for a massive, last-minute bulk run and then switch back to a high mix of box formats, or run both at once, all-in one smooth flow that produces tightly packed and well protected packages.

Meanwhile, material use is significantly reduced – our customers save an average 29% on corrugate, and with the elimination of dunnage, overall material costs are reduced by up to 38%. As packaging material costs continue to increase, for example through the imminent introduction in the UK of Extended Producer Responsibility levies (details as yet unknown, but they aren’t going to be trivial) these savings are significant, as are savings in transport costs through shipping less fresh air. Less quantifiable but still very real, a reduction in packaging waste makes for happier customers.

The bulk packaging sector is well positioned to take full advantage of the big rewards from ‘fit-to-size’ packaging – making ‘unique’ boxes, identically, over and over again.

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