Packsize^®
Smart Packaging for a Healthy Planet®

How many times have you been dismayed by the sheer amount of unnecessary packaging materials around the products you buy?

You are not alone. Around the globe, especially where online shopping has increased exponentially, there are growing concerns about the environmental impact of a glut of packaging materials.

Manufacturing and distribution of packaging materials use enormous energy and resources. Their by-products have adverse side effects, and their disposal is also challenging.

The good news is that many organizations are on a journey to be carbon-neutral and make sustainable packaging a part of their ESG goals.
“Companies prioritizing sustainable packaging can gain a competitive edge by appealing to environmentally conscious consumers. This is crucial to enhance their reputation and customer loyalty,” says Rod Gallaway, CEO of Packsize.

Packsize transforms how businesses and their customers experience packaging throughout the use cycle. Since introducing Right-sized Packaging on Demand^® in 2002, it has evolved as the sustainable packaging industry leader in North America, Europe, and Asia-Pacific. Its ability to create custom-sized boxes for every order drastically reduces waste and ensures cost savings of up to 20 percent.

The hidden potential in a customer’s supply chain is unlocked with custom packaging processes that consider every step of a product’s journey, from the warehouse to a customer’s hands. By reimagining packaging, Packsize leads the way to a more sustainable future.

The Packaging Industry Pioneer

Packsize’s On Demand Packaging^® solutions combine precise, right-sizing technology, accessories, and services required to pack and ship goods directly from a packaging line. These solutions replace traditional store-and-retrieve, pre-made box inventories, and wasteful void fillers. Right-sized custom corrugated boxes are dimensionally superior, cost less to ship, and save resources. Using a right-sized box design also means products are more securely and efficiently packaged.
“We help clients design their custom corrugated boxes, which creates less waste, reduces product damage, accelerates throughput, and generates repeat business,” says Gallaway.

Packsize also builds fully-functional, customized solutions that fit seamlessly into existing warehouse models. This helps clients optimize warehouse space and reduce labor and material costs.

Offering Advanced Systems and Automated Packaging Solutions

Packsize’s integrated, On Demand Packaging solution is powered by a reliable software platform, PackNet^®.

PackNet takes the guesswork out of selecting a box by using automated dimension capture to calculate the best box style and packaging for each shipment. Clients can prioritize box production and send orders to ensure their packages are in the right box style, with the correct z-Fold^®, and at the right induction point.

The PackNet software platform functionality can be customized to the needs of the customer through various modules including PackNet.Report, PackNet.Cube, PackNet. DIM, and CADPack Designer.

The Packsize portfolio of On Demand Packaging systems includes advanced solutions across three distinct series of machines, which are tailor-made to meet the needs of a wide variety of customers. The X Series, for those seeking full packaging automation. The M Series, for highly versatile custom box making. And the IQ Series, for a compact shipfrom-store right-sized packaging solution.

Packsize’s X Series offers smart packaging automation to fast-paced, high-volume fulfilment centers, allowing the reliable packaging and shipping of right-sized single and multi-item orders. It seamlessly integrates with PackNet production and optimization software, which is crucial for creating the most efficient and proven custom box-making experience. This series has recently expanded due with the launch of the X5^®, the world’s first fully automated erected box system.

Widely adopted for its reliability and flexibility, the M Series combines speed and versatility to provide On Demand Packaging solutions across every industry. These multipatented machines stand as a model for automated packaging innovation and excellence.

The next series in the Packsize arsenal is the space-saving IQ Series. It brings the flexibility and benefits of a large on-demand packaging solution at a fraction of the cost. By integrating with PackNet packaging software, businesses can create RSC boxes that fit products of all sizes. It can turn any space into a smart, On Demand Packaging environment with the flexibility to produce small to large right-sized boxes.

These capabilities have helped many clients, including BootBarn, the nation’s largest western and work retailer, which struggled to keep up with demand for their products. The only way to overcome their challenges was by implementing new technology. They turned to Industrial Procurement Services (INDPRO) to help design a better warehouse system. BootBarn wanted to store 250,000 pairs of boots inside their 40,000 square foot warehouse and also have the ability to easily pick and replenish them. INDPRO’s goal was to get 1,000 orders packed, labeled, and delivered every hour.

“In order to hit that number, we needed to bring in automation. Packsize was the obvious choice,” says Mark Juelich, president of INDPRO.

Packsize partnered with INDPRO and BootBarn to build a unique, fully automated solution using three Packsize machine systems. The IQ Fusion, X4, and X7 were the stars of the show. An all-in-one machine, the X7 can take an order, acquire its dimensions, create a right-sized box, wrap it around the order, and place a shipping label on it.

“That, to me, was the most exciting thing about this project. The fact that we could run 75 percent of the products through that machine is amazing,” says Juelich.
The X4 is the most space-efficient Packsize machine system and was perfect for handling complex multis in the BootBarn warehouse. The IQ Fusion is the ideal solution for overflow during peak season while being extremely costefficient. With Packsize and INDPRO working together, BootBarn significantly reduced warehouse labor while doubling throughput and increasing its bottom line. They also reduced their carbon footprint by using less corrugated to make smaller boxes, allowing more boxes to fit on a single truck. BootBarn customers now receive their right-sized packages faster and more efficiently.

Driving toward a Sustainable future

Since the beginning, Packsize has been driven by a goal to make operational processes more economical and environmentfriendly. The vision of producing the right-sized boxes for every order helped reconcile various objectives; resourcesaving packaging, increasing throughput and productivity, reducing costs, and significant CO2 savings in the packaging processes.

Packsize estimates that its customers have collectively saved 681 million pounds of carbon-dioxide emissions since 2013 from the reduction in cardboard use alone. This figure grows daily with its expanding customer base. In addition, it reduces the cubic volume of packages shipped by as much as 40 percent because on-demand packages are right-sized for the product. This plays a pivotal role in reducing shipping costs, leading to fewer trucks on the road or planes in the air, for less air pollution per package.
Packsize currently powers its headquarters in Salt Lake City, UT, and its factory for sustainable packaging machines in Enkoping, Sweden, with renewable energy sources. It also discourages using non-renewable resources in its daily operations and advocates reducing, reusing, and recycling all paper, plastic, and aluminum materials across the organization.

The drive toward a sustainable future and a healthy planet will continue to fuel Packsize’s smart packaging solutions for years to come.