Executive Summary

FlexPAC worked with an electronics shipping, 3PL company to find an eco-friendly replacement to their current void fill machines. Before FlexPAC’s solution, workers were using another paper-based void fill solution, which required much more operator attention. This manual process often led to jamming and bottlenecked their entire process and void fill feed rate. FlexPAC’s solution was to implement an eco-friendly, automated system that cut and removed the paper itself. This completely resolved their bottlenecking issues, prevented future workplace injuries stemming the manual process, and eliminated all jams. With the bottleneck removed, the company’s package output increased by 20%, and they were able to save $12,000 from preventing downtime and eliminating additional paper waste.


Previously, the company had a constant, internal struggle with their void fill machines. The machines required the manual removal of paper, the large rolls often jammed, and they struggled to keep up with the constant demand of shipping 2,000 to 10,000 packages per week. Before the automated process was added, employees were also frequently at risk of back injuries with manually changing out the large paper rolls. Because of complications to production issues and the threat to workplace safety, a change needed to be made. FlexPAC’s replacement had to reduce complexity and offer usability in hopes of preventing workplace injuries and increasing productivity. However, the company also wanted to reduce their carbon footprint.

FlexPAC’s Process

After research and assessment of the situation and needs, FlexPAC suggested implementing the Ranpak FillPak TT. The solution’s installation was simple, quick, and was added at each packaging table to maximize production speed. Previously, the company had employees manually removing the paper. Today, the Ranpak FillPak TT instead fills and cuts each box’s void fill requirement to perfection. FlexPAC’s solution also completely removed the manual process, which eliminated the bottleneck and was also eco-friendly.


FlexPAC’s solution eliminated the production line’s bottleneck and increased their output per hour by 20%. This automation addition also allowed workers have more time to focus on other tasks. Because the Ranpak FillPak TT’s were smaller in size, they also decluttered the workspace and eliminated paper waste. In all, the company was able to save $12,000 per year from previously wasted paper, the cost of downtime, and labor costs. After time with the new solution, the company’s shared, “Our packers really love the auto cut feature and the fact the machines are easy to load and never jam.”

Void fill machine


Curious how we can help you?

Contact us for a free needs analysis and start optimizing your warehouse.