For many manufacturers and distributors, packaging is one of the last areas to be optimized—but it’s often one of the most impactful. Whether you're managing a high-volume production line or a regional distribution center, inefficiencies in your packaging process can lead to:
Increased labor costs
Slower throughput
Product damage and returns
Missed shipping deadlines
The good news? Many of the most common packaging problems can be solved quickly, sometimes in just a single day, with the right automation tools, systems, and support.
Below are five packaging challenges you might be facing—and how to fix them faster than you think.
Manual or outdated sealing methods often result in uneven tape application, open flaps, or poorly secured boxes. This can lead to product damage, increased returns, and a lack of professionalism in your outbound shipments.
Invest in a semi-automatic or fully automatic case sealer. These machines deliver consistent, secure seals every time and can be integrated into your current packaging line with minimal downtime, often in just a few hours.
Bonus Benefit: Switching from hand-taping to machine-taping can significantly cut tape costs. Machine-applied tape uses less material, reduces waste, and requires fewer roll changes—saving you time and money.
Explore case sealer options tailored to your operation here.
Many packaging lines still depend on multiple workers to handle repetitive tasks like taping, wrapping, or palletizing—jobs that are not only time-consuming but also prone to human error and fatigue. This drives up labor costs and reduces overall efficiency.
Automating with equipment like stretch wrappers, case erectors, and palletizers can dramatically cut labor needs while boosting consistency and throughput. These systems are scalable and customizable, making them a smart fit for operations of any size.
Bonus Benefit: Automation also improves workplace safety and ergonomics. In today’s tight labor market, protecting your team and keeping them satisfied is more important than ever.
Curious how much time and labor you could save?
Chat with an equipment specialist to request a free ROI analysis and get a tailored quote to reduce your packaging labor costs.
When demand spikes, manual packaging processes often can’t keep up. This creates bottlenecks that delay shipments, increase overtime, and reduce customer satisfaction.
Targeted automation, like faster conveyors, print-and-apply labelers, or modular upgrades, can dramatically increase throughput without requiring a full system overhaul.
Browse in-stock packaging equipment here to help reduce those bottlenecks you could be experiencing.
Using the wrong box sizes, overpacking, and inefficient material usage can quietly drain your budget and inflate your environmental footprint. These issues are especially common in operations that haven’t revisited their packaging strategy in years.
Right-sizing equipment and eco-friendly packaging materials can significantly reduce waste, cut shipping costs, and boost your sustainability metrics. Many of these solutions are available as turnkey systems that are easy to implement.
Bonus Benefit: There are affordable ways to add automation and efficiency to your daily workflow, like Tach-It tools and entry-level automation equipment. These small upgrades can make a big impact.
Want to uncover hidden inefficiencies in your process?
Chat with a packaging specialist for a free automation and efficiency audit tailored to your operation.
Without data, it’s hard to identify where your packaging process is underperforming. Many companies operate without clear metrics on throughput, downtime, or material usage.
Modern packaging systems often include built-in analytics and reporting tools. For example, the iTrack system from IPG provides real-time insights into case sealing performance, helping you monitor efficiency, reduce downtime, and make data-driven decisions.
Watch how the iTrack system delivers real-time packaging analytics below.
If any of these issues sound familiar, you're not alone. The good news is that many packaging problems can be solved quickly—with the right tools and support, improvements can often be made in just a few days, especially when automation equipment is in stock and ready to go.
Want to explore your options? Chat with a packaging solutions specialist to get recommendations for your business needs, pricing, and an ROI analysis tailored to your operation.
Don’t miss the Twin Cities Packaging Expo, held every September. This Minnesota packaging expo is a free, one-day event where you can see the latest packaging technologies in action, connect with industry experts, and get hands-on help with your challenges—all in one place. Click here to learn more and register.