This article first appeared in the April 2025 issue of ProPack.pro magazine, authored by DieLine Solutions’ Ian Gillanders

Australia’s packaging producers face a tough challenge. Labour is expensive, and repetitive manual tasks – like lifting heavy boxes all day – make jobs at the end of the folder-gluer line difficult to fill. Did you know that a single worker can lift and pack up to nine tonnes in a single day? That’s a massive strain on the body. But what if we could make these jobs more attractive, safer, and more productive?

Automation is key. It doesn’t just lighten the load, it removes the most physically demanding tasks, making jobs more ergonomic and engaging. Instead of lifting cartons all day, workers operate and oversee automated systems.

And the benefits go beyond individual well-being: staffing shortages and absenteeism due to injury are real concerns, and hand-packing with a skeleton crew means slower speeds and lost efficiency. When automation steps in to do the heavy lifting, finishing lines can maintain peak output – even with fewer people on the floor.

Smart solutions for a complex industry

In the folding carton and tray-forming sector, speed limitations at the packing stage have long been a bottleneck. While full automation works for some, other producers need the flexibility to do many box types on a single finishing line. Recognising these issues, IMPACK has developed innovative semi-automatic solutions such as the ERGOSA.

These systems bridge the gap between full automation and manual labour, providing flexibility, fast changeovers, and ergonomic benefits.

The impact of these solutions is remarkable.

One local packaging producer installed an ERGOSA and, after a short training session, put it to work. On its first run, a single worker packed 40,000 boxes per hour of a specific box type. I suggested they test its full potential, and after increasing the speed of their folder-gluer, they hit 60,000 boxes per hour without breaking a sweat. Before the ERGOSA, two workers packing manually could only manage 20,000 per hour of this box type. This isn’t a one-off case – facilities worldwide are seeing similar gains after implementing IMPACK solutions.

Fast payback, lasting benefits

Automation isn’t just about improving working conditions – it’s about boosting profitability. With production numbers and labor costs, it’s easy to calculate the payback period on automation, and in the case of IMPACK solutions, it’s a matter of months before the machine starts delivering pure profit.

Innovation meets the tray forming line

I’m always on the lookout for cutting-edge solutions that give my clients an edge. For years, I’ve supplied Gietz Tray Formers and until recently, there weren’t any solutions to help with end of line tray packing. But this year, IMPACK is introducing the TRAYVA, a semi-automatic packing system designed for tray formers, unlocking higher productivity and improved labour utilisation. It’s so efficient that a single operator can pack for two tray-forming machines.

Value through superior solutions

My commitment has always been to provide packaging producers with high-quality solutions that address industry challenges and maximise long- term investment value. I also represent MARBACH flatbed/rotary die-cutting tooling in the A/NZ market – a premium, German-engineered product renowned for its performance and durability.

Another standout innovation is Policart Anvils, which significantly extends the lifespan of cutting tools while enhancing precision for the fibre/corrugated converting market. By improving cutting accuracy and lasting longer, these Anvils help businesses reduce costs and increase efficiency, delivering tangible benefits in a highly competitive market. Innovation is the driving force behind industry advancement. The right automation does more than boost output; it revolutionises operations, making packaging producers more resilient, efficient, and profitable.