RIGHT-SIZED automated packaging systems provide a fit-to-size box for each individual customer order. There are various technologies to choose from, with many leveraging AI to ensure the ultimate in precision and efficiency.

There are many benefits in using right-sized packaging automation and the savings can really add up. The costs involved in packaging are often underestimated – it is typically the second most labour intensive process after order picking. With automation, the time spent erecting the box is eliminated, along with the time filling it and the guesswork involved in selecting the appropriate size of box for the order.

Then there is the cost of shipping. With most carriers calculating shipping costs based on dimensional weight (DIM weight), oversized boxes obviously cost more to ship. For companies with their own vehicle fleets, having right-sized parcels means that more orders fit in each lorry, reducing the number of truckloads and resulting in lower fuel consumption. Of course, this also secures environmental gains through reduced CO2 emissions. This has the knock-on effect of enhancing brand image among eco-conscious customers, who will also notice and appreciate the more sustainable unboxing experience.

In addition, there are advantages in terms of product protection. A right-sized box helps prevent collision of the items inside against each other or the box itself. It also minimises the cost – plus labour and material waste – of the void fill material typically used in oversized packaging to mitigate the risk of product damage. In this way, right-sized packaging helps to reduce the number of costly returns and to enhance customer satisfaction.

The trend towards adopting right-sized packaging systems was given a boost by the European Union last year when it passed new regulations that limit the amount of empty space in packaging. The Packaging and Packaging Waste Regulation 2025/40 (PPWR) – which came into force on 11 February 2025 and will generally apply from 12 August this year – stipulates that packaging should not have more than 50% empty space by 2030.

Two AMHSA members – Friedheim International and Sparck Technologies – specialise in packaging automation, while many of our members offer right-sized packaging technologies as part of their material handling solutions, along with dimensioning systems that can automatically create a digital profile for every SKU in your warehouse.