AN automated solution provided by Yorkshire Packaging Systems (YPS) using Hugo Beck’s flexo e-com machine has reportedly helped fashion accessory specialist totes ISOTONER (UK) to fulfil five times its previous daily order capacity.
With a product range featuring the original totes toastie slipper-sox (socks with slip-resistant soles) plus gloves, scarves, slippers, umbrellas, wellies and sheepskin boots, the brand is stocked in stores across the UK and also runs an e-commerce service.
Prior to the recent investment, dispatch of orders involved a manual pick and pack process whereby goods were loaded by hand into a choice of three different sized, pre-formed, loose mailing bags.
In early 2022, totes approached YPS with the requirement for an automated machine capable of achieving target speeds of 720 packed bags per hour. The solution also needed to sync with its existing ERP systems and allow totes to reduce reliance on Royal Mail’s data system by including high-speed and GDPR-compliant courier label printing.
Tom Hill, sales manager at YPS, said, “To measure up to totes’ needs, YPS recommended the horizontal Hugo Beck flexo e-commerce automatic bagging unit, with an internally mounted VULCAN direct apply labeller from Clearmark. Hugo Beck’s solution is tailored specifically to coping with the demands of a busy e-commerce packaging line, with its high-speeds, high volume and data security.
“Replacing totes’ original grey mailing bags with precise-fitted packaging, the machine is able to accommodate over 95% of totes’ product range, from single pairs of socks right up to boxed pairs of wellies. It is this responsiveness to product dimensions which makes the flexo e-com system ideal for totes’ dynamic, busy warehouse. The production does not need to be batched.”
To maintain brand consistency, YPS replicated the plastic film used on the new line with the original preformed bags by colour matching the shrink film, creating 525mm 50mu polythene which is 100% recyclable with a 50% post-consumer waste blend.
The machine scans each order’s unique printed barcode and the correct customer address label is recalled by the VULCAN. The length of each product is also detected and the flexo e-com machine then tailors the bag length to ‘precisely match’.
The bag width can be adjusted with a wheel winding mechanism. Before destroying the data in a ‘one in, one out’ method, the label is applied to each bag via an all-electric system using continuous motion of the VULCAN.
At sign off the solution achieved a speed of 1,080 packs per hour – a daily order output five times greater than pre-install.
“Investing in this equipment from YPS has proven to be a game-changer,” said Karl Blackburn, operations director at totes ISOTONER (UK). “We’ve radically increased our throughput, allowing us to complete more online order despatches in a faster timeframe and please more of our customers.”
