Right-sized boxes and envelopes on demand in a single machine

CMC CartonWrap DUO is a game-changing machine that packs items of different dimensions in right- sized boxes or envelopes on demand. CMC started its revolutionary journey in 2013 with the launch of the CMC CartonWrap, the world's first fully automated right-sized packaging machine. This innovation creates right-sized boxes for items of varying shapes and sizes and significantly reduces packaging volumes, cardboard waste, and CO2 emissions across various industries.

The CMC CartonWrap DUO exemplifies CMC's commitment to innovation and excellence, setting a new benchmark in sustainable and efficient packaging. Addressing the rising demand for eco-friendly solutions with high ROI, this machine redefines packaging automation. The CartonWrap DUO customizes right-sized boxes or envelopes based on product dimensions and thickness, eliminating the need for traditional pre-glued packaging. It processes up to 900 packages per hour, handling diverse items like apparel, electronics, and books, with product thicknesses ranging from 1 mm to 250 mm. A standout feature is its integration with the CMC Wave Line, an inline cardboard coupler that produces corrugated material on demand. By eliminating pre-stocked corrugated materials, it cuts storage needs and costs. Material usage is reduced by up to 50% compared to conventional methods, while glue consumption decreases by up to 70%, offering a significantly more sustainable option. The ability to produce postal-eligible envelopes provides added savings for retailers and 3PLs. The CartonWrap DUO tackles operational challenges such as labor shortages and workflow inefficiencies by automating packaging processes, minimizing manual intervention, and consolidating functions into a single machine. It ensures precise cutting, folding, and sealing for custom-fit packaging, eliminating void fillers, reducing waste, and maximizing shipping efficiency. These optimizations lower CO2 emissions and enhance overall sustainability. Beyond functionality, the system improves customer experience by reducing damage, missed deliveries, and return-related costs. Whether deployed in greenfield or brownfield environments, the CartonWrap DUO integrates seamlessly, boosting efficiency while delivering measurable environmental benefits. This innovative solution represents a cornerstone of sustainable packaging automation.

We wanted to revolutionize packaging with a flexible, sustainable, and efficient solution that addresses labor shortages, environmental challenges, and rising material and warehouse space costs. The machine has successfully overcome technical complexities in creating a dual-function machine capable to process both boxes and envelopes based on product thickness, ensuring seamless integration, and optimizing ROI for diverse applications.

The packaging process includes the following steps:

1. Scanning and Measurement: The process begins with scanning the item to be packaged. It uses advanced scanning technology to precisely measure the dimensions of the item.
2. Box/envelope Creation: Based on the measurements obtained, the machine designs and creates a custom-sized box or corrugated envelope from a continuous roll of corrugated cardboard. It cuts, folds, and seals the cardboard to form the tailored shape.
3. Item Insertion: Once the box/envelope is formed, the item is gently placed inside it. The machine ensures a snug fit to minimize movement and potential damage during transit.
4. Gluing and Sealing: The machine applies low impact glue to secure the final packaging flaps in place, creating a fully enclosed and well-sealed pack.
5. Labeling and Dispatch: Once the box/envelope is sealed, it applies a shipping label or prints onto the package for identification or branding purposes. The finished package is then sorted and ready for shipment.

The CMC CartonWrap Duo already incorporates numerous innovations in automation and sustainability. We collaborate closely with our strategic supply chain partners to continuously improve the impact of consumables. Together, we strive to identify paper and other materials that can further reduce packaging environmental footprint. Additionally, we are actively working with system integrators to enhance integration processes for both greenfield and brownfield projects.

Based in Olching, Germany, Printhouse GmbH is a premium printing and finishing services company under the ALL IN Group, associated with MYPOSTER. Specializing in high-quality products such as greeting cards, photo books, and calendars for brands like Kartenliebe.de and MYPOSTER, the company demonstrated its commitment to innovation in 2024 by acquiring three Scodix print enhancement machines, enabling premium finishes like gold, silver, and rose gold. Operating from a 5,000-square-meter facility with 52 employees, Printhouse projects enhancing 6 million cards in 2024 while delivering luxurious products without price increases. In early 2024, Printhouse faced significant fulfillment challenges due to rapidly growing volumes, labor shortages, and peak season pressures. To address these issues, they partnered with CMC Packaging Automation. After rigorous tests, the CartonWrap Duo was installed in October 2024, transforming their operations just before peak season. Key Benefits: Labor Optimization: Eliminated the need for additional staff during peak season, enabling 10-15% annual growth with the same workforce. Peak Season Performance: Shipped up to 8,000 orders daily, with a best-day performance of 7,200 boxes in two shifts. Packed and shipped 144,000 parcels in 24 days between Black Friday and Christmas. Cost Savings: Reduced packaging costs by €0.20 per box, saving €28,800 during the peak period. Process Efficiency: Cut manual workload per order by 50% and reduced warehouse space usage by 75% with fanfold corrugated material. Scalability and Stability: Achieved 100% on-time shipments since implementation, with no backlog during peak demand. Sustainability is central to their operations. The CartonWrap Duo enables right-sized packaging, reducing material waste and aligning with PPWR regulations. This innovation underscores Printhouse’s commitment to eco-friendly practices while setting new industry standards for efficiency and customer satisfaction.

https://www.printhouse.de/ www.cmcsolutions.com