Challenge

Jollyroom specialises in baby and children goods. The e-shop has a large range of products from strollers and beds to toys and children’s clothing.

This wide range makes them unique in the market, but it also entails many internal challenges, especially when it comes to packing and sending goods of such great variety in the most efficient and optimal way.

The major factor in choosing the right supplier was that the system was not relying on knives, but on a folding system instead. Cardboard knives need to be changed at regular intervals which would have stopped the entire flow for short periods. Stopping the production for just five minutes would have had consequences for several hundred orders and during high-intensity periods like the Black Friday Week and Christmas shopping, this would have been untenable for them.

Solution

The system they have chosen consists of three machines that erect cartons and two machines that scan the product size, fold down the edges and close the cartons in an optimized size based on each product. Instead of tape, the machine uses a very strong adhesive that minimises the risk of damage during transport. By perforating the seal, the shipment becomes easy for the customer to open.

The automated packaging solution is connected to the company’s storage system and an automated sorting system. Together, the three systems form an automated logistics solution for small and mid-sized goods.

Results

The new system can produce up to 1560 cartons per hour and will double the efficiency of the entire delivery flow for small and mid-sized goods.

Previously it used to take up to two minutes on average to manually pack an order of which much of the time was spent on transporting cartons. With the new installation, the packing operation takes about one minute, which means that we doubled the efficiency of the flow.

Optimising the packaging of goods has not only had a positive impact on the packaging process and customer satisfaction; it is also part of a long-term environmental effort to bring down the company’s overall environmental footprint. The automated packaging solution has helped to reduce the total loading volume of small and mid-sized goods by up to 60% and, in addition, no cushioning or void-fill materials are now required inside the cartons. This both reduces the environmental impact and lowers transport costs.

Planning is in place to extend this automated solution, which will support the extensive growth and cope with the future competitive situation in this market.

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