Ecommerce growth is making transit packaging a strategic cost issue for fulfilment operators. Individual orders vary widely in size and contents, while fixed carton ranges can leave excess space and require labour-intensive packing.
UK online retail represented 27.4% of consumer spending in 2025, rising to 29.9% in the fourth quarter, according to the ONS Retail Sales Index. Ofcom’s 2025 parcel report recorded 4.2 billion parcels sent and received by UK consumers during 2024.
Automated right-size systems respond by measuring each order and producing a corrugated box to match it. Packsize offers semi-automated and fully automated solutions, with equipment capable of forming and sealing up to 1,300 packages per hour.
The company reports average corrugated-material savings of about 30%, package-volume reductions of up to 40% and roughly 80% less void fill. Fully automated equipment can deliver output comparable to around 20 manual packing stations, although performance varies by product mix and operating model.
The technology can also support box-first and box-last fulfilment. A tray can be created before picking and closed afterwards, removing the need for plastic pick totes. Smaller cartons may improve vehicle utilisation and reduce journeys, fuel use and emissions.
Packsize says its systems can be introduced in existing warehouses or incorporated into new facilities, with integration to warehouse management systems.
A multilingual professional experienced in Europe, Canada, and China, Herbert has developed invaluable networks in the automotive and energy industries. He has led high-profile projects involving ENBW, Mercedes-Benz Group, Siemens Group, and the Fraunhofer Institute.