The Hidden Power of Packaging: Why the End of the Line Deserves a Fresh Look

By Bryan Boatner, Global Managing Director of Automation, Ranpak

When people think about warehouse automation, packaging doesn’t always make the shortlist, but it should.

At Ranpak, we’ve seen how right-sized packaging systems can dramatically reduce waste, streamline labor, and enhance the customer experience. But what’s even more exciting is how packaging automation can act as a gateway to broader warehouse improvements.

The Downstream Advantage

Automating the end of the line might seem like the final step, but in practice, it often becomes the first move toward a more modern fulfillment model. When you resolve downstream bottlenecks, you start to see how inefficiencies flow backward through your operation. That visibility helps warehouse leaders make more informed decisions about where to focus their next investments.

Smarter Systems, Real Results

Our DecisionTower™ system is a great example of what this can look like in action. It uses machine vision to analyze void space in real time and automatically dispense the right amount of recyclable paper fill. This approach minimizes material waste, improves cycle times, and enhances packaging consistency, even when incoming order data isn’t perfect.

Built for Flexibility

Adaptability matters. Many warehouse operators struggle with inconsistent product data or unpredictable order volumes. That’s why we design our systems to be resilient and self-correcting. Whether it’s accommodating SKU variability or adjusting fill levels on the fly, the technology is built to perform reliably without requiring a perfect environment.

Designed for Ease of Integration

We also prioritize modularity and maintainability. Our systems are designed to integrate easily with your existing workflows and grow alongside your business. They don’t require a complete overhaul or full-time resident engineers — just smart implementation and occasional support. That keeps costs down and empowers your internal teams to take ownership of the equipment.

Value Across the Board

For 3PLs and retailers alike, right-sized packaging creates value across the board:

• Reduced labor and freight costs
• Lower carbon emissions and packaging waste
• Fewer damaged items and returns
• A faster, more consistent fulfillment process
• A better, branded unboxing experience for customers
• Meeting sustainability expectations

There’s also the sustainability factor. As regulations around packaging waste continue to tighten, businesses need to demonstrate environmental responsibility. Automated right-sized packaging helps meet these requirements while improving operational metrics, which is a true win-win.

Start at the End, and Scale from There

If you’re considering automation in your warehouse, don’t overlook the impact packaging can make as a foundational step.

Hear more on the “Warehouse Automation Matters” podcast.