At its National Distribution Centre in Nieuwegein, Jumbo and WITRON unveil a concept that redefines the role of modern logistics hubs. The focus: speed, availability, and agility. Covering 40,000 square meters, the facility supplies over 725 stores in the Netherlands and Belgium with nearly 3,000 different fresh and ultra-fresh items, including dairy products, a wide selection of cheese, meat products, tapas, salads, chilled beverages, and much more. At an ambient temperature of +2 degrees Celsius, more than one million units can be picked daily using OPM (30 COM machines), AIO, and CPS modules. A fully automated shipping buffer ensures just-in-time dispatch of store-friendly stacked roll containers to the markets.

The fresh distribution centre marks the second successful collaboration between Jumbo and WITRON, following a high-performance dry goods facility. Equipped with OPM (31 COM machines), DPS, and CPS, this site can pick up to 565,000 cases on a peak day from a range of 14,300 items.

DC Heart of Supply Chain

The Dutch retail group faced a series of challenges that necessitated the construction of one of Europe’s most ambitious logistics platforms. These challenges included expected labour shortages in the future, expanding assortments in both the dry and fresh food sectors, rising consumer expectations – especially for fresh products – and growing demand for speed in both stores and online channels. Today, the highly automated fresh logistics centre in Nieuwegein, designed and implemented by WITRON as a lifetime partner, serves as the strategic centrepiece of a supply chain that is seamlessly orchestrated, adaptive, and more customer-focused than ever before. Because the consumer is the true pacesetter.

Mechanics and IT

The central distribution centre for fresh products (CDC) is designed for a daily peak capacity of 1.06 million picking units. A modular expansion for future growth has already been considered in the overall concept. All logistics areas are connected by a conveyor network that includes more than 670,000 pallet, tray, and tote storage locations, as well as 120 stacker cranes. Everything is controlled by a highly functional WITRON warehouse management system. All IT and mechanical components have been designed, manufactured, and put into operation by WITRON.

Labour, Range, Freshness

When Jumbo began shaping the future of its supply chain a few years ago, it became clear that existing structures could not meet the challenges ahead. “We expected to face challenges in the labour market, anticipated a growing number of SKUs, and set out to fundamentally redesign our fresh logistics with a clear focus on maximum customer service, freshness and sustainability,” recalls Karel de Jong, Supply Chain Director at Jumbo. The company aimed to broaden its SKU portfolio, sharpen assortment differentiation, and drive greater agility across its fresh logistics operations. At the same time, regional warehouse space became increasingly constrained as the product range continued to expand. The solution developed focused on centralizing, automating, and streamlining processes.

Precise time management is of critical importance, especially in the ultra-fresh segment. Temperature, daily operations, and weather conditions immediately impact volume.

“For us, agility means being able to respond very quickly to changing demands. A shift in weather means a shift in demand, and we need to be ready to respond,” says de Jong. “Freshness must reach the consumer’s table without delay – and not remain in the warehouse.”

The project marked a significant shift in WITRON’s internal approach. The warehouse has evolved from a standalone entity into a seamlessly integrated organ within the supply chain orchestra. Johannes Meissner, WITRON’s Technical Managing Director describes the development as follows: “The DC is no longer an isolated system, but an integral part of our customer’s organism. Only then can supply chains truly be optimized.” This transformation turns the warehouse from a pure consolidation and buffering point into a key control instrument. de Jong adds: “However, the DC does not lead the orchestra. The customer does.” Symbolically, he portrays the warehouse as the ‘first violin’ in a finely tuned supply chain orchestra – vital, leading, and setting the tone, but always part of a greater harmony.

Technology in XXL

The Nieuwegein logistics hub, featuring both dry goods and fresh food distribution centres, ranks among WITRON’s largest projects worldwide. It is equipped with more than 60 COM machines, over 1.1 million pallet, tray, and tote storage locations, approximately 200 stacker cranes, and is designed for a maximum capacity of 1.6 million picks per day. With OPM, AIO, CPS, and the automated shipping buffer, the Upper Palatinate team leverages proven technology. It guarantees peak availability, since the DC is the core of supply for Jumbo customers in the Netherlands and Belgium. An onsite service team ensures seamless operation of all IT and mechanical processes.

Both partners emphasize that success is not a matter of machine count, but of the specific requirements within each area of use. How can the system be balanced? Since all items are delivered to the stores on roll containers, seamless coordination between the subsystems is crucial to achieve maximum consolidation and space utilization. According to de Jong: “Success is not about the next machine. It’s about a perfectly tuned overall concept, with a vital role for the operators and control room team.”

Result in the Store

Automation delivers measurable benefits for the stores:
• More SKUs – with an upward trend
• Automated stacking of goods onto roll containers, tailored to the store’s shelf layout
• Consolidation of cases (picked in OPM and CPS) with pieces and totes (picked in AIO)
• Highly efficient, route-optimized truck loading enabled by advanced optimization processes within the automated shipping buffer

As a result, shelves in the store are replenished more efficiently, faster, and with less handling effort. In addition: processes previously managed via direct delivery – such as fresh fish – are now consolidated via Nieuwegein. And thanks to advanced forecast and replenishment processes, Jumbo delivers exactly what the stores truly need. The outcome for customers is enhanced freshness, a perfectly tailored assortment, and faster availability.

Packaging is a Core Competence

Automated processes require standardization, and this is reflected in the way various types of packaging are managed. “That’s why we have trained colleagues who have developed extensive expertise in this area,” says de Jong. Carton design, adhesive properties, stretch film, as well as cardboard and pallet quality are critical for material flow and load stability. WITRON and Jumbo took early action to identify critical packaging and deliver transparency to suppliers. The outcome is enhanced inbound control, resulting in more stable processes within the DC.

Employees at Jumbo were able to adapt effectively to their new tasks, moving from manual operations to an automated production process. Employees were able to gain detailed insights into future tasks within operated systems and engage in extensive exchanges with experienced users. “With a wealth of experience from projects implemented across Europe, North America, and Australia, we can offer customers comprehensive support in this vital field of change management,” emphasizes Meissner.

Technology can be purchased – culture cannot. Jumbo adopted lean principles with the Jumbo Production System (JPS), including shopfloor transparency, shift stand-ups, and a high degree of autonomous problem-solving by employees. Once a day, a central control meeting is held at the very centre of operations – not in an office, but in the work area. “Here, the colleagues analyse the previous day and review the tasks and goals for the upcoming shift. If this half hour goes well, it will be a good day,” says de Jong with a smile.

What measures can be expected next? Jumbo considers the supply chain to be an end-to-end network structure rather than a set of separate warehouses. Integrating stores, connecting with suppliers, optimizing transport routes, and automating processes – including in e-commerce, which is still handled manually today – are key pillars of the future strategy.

“Automation is not a standalone objective, but a tool applied where needed. Variety in our product range continues to define our corporate philosophy – driven by a clear focus on efficiency and economic viability,” states de Jong. Meissner gets straight to the point: “Automation built the foundation. The next chapter is all about end-to-end optimization.”

The post High-performance Warehouse Automation appeared first on Logistics Business.

Loftware, a global supplier of product identification equipement, today announced the release of its 2026 Top 5 Trends Report, revealing that businesses worldwide are moving urgently to modernize their supply chains in the face of unprecedented disruption, geopolitical uncertainty, and increasing regulatory demands.

Drawing on insights from more than 400 supply chain professionals across 55 countries, the report highlights a decisive shift toward connected supplier networks, real-time packaging intelligence, and AI-enabled automation as organizations work to strengthen resilience and stay competitive in an unpredictable global landscape.

“The future of supply chains will be defined by agility and intelligence…Our research shows that organizations adopting connected networks, cloud platforms, and AI-driven insights are not just surviving disruption but turning it into opportunity. By modernizing today, companies can anticipate challenges, act in real time, and create supply chains that are smarter, faster, and ready for whatever comes next.”

said Jim Bureau, President & CEO of Loftware.

The research underscores how volatility has become the defining feature of today’s supply chains. Yet many organizations remain unprepared: according to Gartner data, only 29% of companies are ready to manage the next wave of supply chain challenges. At the same time, financial pressure is intensifying. Among companies surveyed with a revenue of $1 billion or more, 50% expect tariffs or trade restrictions to cost them over $1 million in the coming year, with nearly one in five anticipating an impact exceeding $10 million.

According to the report, companies are responding by accelerating investment in solutions that unify supplier ecosystems, ensure consistent and compliant product data, and reduce the operational friction caused by siloed processes. Nearly 70% of respondents believe that sharing label data and standards with trading partners would help them respond faster to disruptions; an indication that the industry is moving quickly toward more collaborative and connected networks. Organizations that have already adopted such models report measurable gains, including 48% citing faster problem resolution and 37% citing reduced operational costs.

The findings also reveal that geopolitical uncertainty is forcing businesses to rethink compliance strategies. Many organizations still struggle to adapt product data and labeling processes to new tariffs or regulatory changes, with 63% of $1B+ companies calling these adjustments “very” or “somewhat difficult.” As supply chains move through reshoring, nearshoring, and multi-sourcing, cloud-based labeling is essential for accuracy and compliance across shifting supplier networks, helping companies avoid costly delays, border holds, and penalties.

Consumer expectations are driving transformation as well. Smart packaging, powered by real-time label data, dynamic QR codes, and connected product information, is emerging as a critical tool for improving engagement, sustainability, and operational efficiency. According to the research, 91% of respondents believe real-time label data helps reduce waste, errors, and improves efficiency. Companies view enhanced traceability (64%) and improved consumer engagement (44%) as the top benefits of connected packaging, illustrating how brands are beginning to treat packaging not just as a regulatory requirement, but as a strategic channel for data, transparency, and customer experience.

Authenticity and traceability are now essential in modern supply chains, accelerated by initiatives like Digital Product Passports and next-generation 2D barcodes. With consumers, regulators, and trading partners demanding verifiable product information, 88% of respondents say cloud-based product identification platforms establish a single source of truth to ensure accurate tracking, traceability, and authenticity. The research illustrates that strengthened traceability improves compliance (43%), visibility (40%), audit readiness (34%), and counterfeiting protection (27%).

Loftware’s report shows that autonomous supply chain technologies are gaining traction. Powered by SaaS-based labeling platforms, AI analytics, and integrated data, these systems help detect disruptions earlier, optimize logistics in real time, and automate error-prone processes. Seventy-five percent of respondents use SaaS-based labeling for resilience, citing benefits like higher efficiency (41%), fewer errors (37%), lower waste (33%), and faster response (30%). As companies face greater complexity across supplier networks, these capabilities will play a central role in building supply chains that are not just connected, but intelligent and self-optimizing.

The post Supply Chains Race to Modernize Amid Disruption appeared first on Logistics Business.

Sustaining growth through smarter logistics

In recent years, Volpak’s growth has accelerated, driven by the global success of flexible pouches — a format that fits the modern, fast-moving lifestyle and offers strong sustainability advantages. As demand and production volumes grew, so did the internal movement of parts and sub-assemblies, putting pressure on both space and workforce. The company faced a clear challenge: how to handle higher logistics complexity while maintaining flexibility, quality, and efficiency within the existing footprint.

From push to pull: a new logistics philosophy

Volpak’s answer was a complete shift from a ‘push’ to a ‘pull’ material-flow model, where every movement responds directly to production demand. The first milestone came two years ago with the introduction of autonomous mobile robots (AMRs) that deliver selected components from the warehouse to the assembly lines. The new phase brings full system integration: a fully automated warehouse synchronized with three AMR connected to the production floor and synchronized with three AMRs, ensuring seamless, just-in-time delivery of materials.

A compact factory, a complex challenge

Volpak’s Barcelona site is spread across two levels — a configuration that naturally limits traditional warehouse expansion. To overcome this, the new system leverages vertical conveyors, high-density storage, and multi-level transport routes, creating a continuous material flow across the plant. The resulting architecture introduces a multi-level material-flow system designed to maximize capacity and minimize travel time. Each component, from inbound goods to production orders, is tracked and routed automatically through intelligent conveyors and buffer zones, linking warehouse, inspection, and assembly areas with precision timing.

Data, segmentation, and efficiency

Before implementation, Volpak performed a complete analysis of its more than 40,000 Stock Keeping Units (SKUs) — unique codes used to identify each part or component stored in the facility, classifying them into A-B-C categories based on frequency and movement. The resulting setup now dedicates high-throughput areas to ‘A’ parts (representing 80% of movements) while lower-demand components are efficiently stored in deep racks. The new automated storage system provides over 50% additional storage capacity and scalability, allowing the company to absorb an expanded SKU portfolio. The integration of autonomous robots that handle boxes directly within the racking system ensures high throughput with minimal footprint.

An ecosystem built for Lean excellence

The project consolidates Volpak’s ‘Lean Transformation’ path, which has already improved assembly areas and introduced Just-in-Time principles across operations. With the new setup, material preparation follows a ‘one-piece flow’ logic: production orders are assembled and delivered as complete kits, minimizing waiting times and ensuring that every group has exactly the parts needed to start work. The result is a faster, cleaner, and more ergonomic process that reduces handling, improves safety, and enhances operator efficiency.

Benchmark for operational future

Entirely designed and managed by Volpak’s internal teams — with Coesia’s engineering and digital expertise as enabler — the new intralogistics system represents a scalable model that could inspire similar evolutions across the Group. It embodies the convergence of Lean principles, smart automation, and advanced logistics design — proving that even a multi-level, space-constrained facility can achieve world-class operational excellence through intelligent planning and innovation. Looking ahead, Volpak’s new intralogistics architecture strengthens its role within Coesia’s long-term strategy, setting a clear path toward fully connected, Industry 4.0–ready operations and positioning the Barcelona plant as a reference model for future advancements across the Group.

The post Lean Logistics Transformation for Packaging Firm appeared first on Logistics Business.

RFID is a word we see a lot, perhaps without understanding the term fully. Please explain what RFID is and why it is a transformational technology in logistics.

“RFID, or Radio Frequency Identification, is a technology that allows assets to be identified, tracked, and managed automatically and without direct visual contact, using radio waves. Unlike barcodes, which require manual scanning and a line of sight, RFID systems can read hundreds of items simultaneously, even when they’re inside closed boxes or in motion. This not only increases speed but also improves the accuracy of intralogistics processes.

“Within the RFID universe, there is RAIN RFID, a global standard based on UHF (Ultra High Frequency) technology that enables wireless communication between tags and readers with greater range and faster read speeds. RAIN RFID is the technology that makes possible many of the item-level traceability solutions used today in sectors such as retail, sports, fashion, cosmetics, and even healthcare.

“At Clustag, we work specifically with RAIN RFID because it forms the foundation for developing robust, scalable, high-performance solutions tailored to modern, automated, or semi-automated logistics centres. This is the technology that powers our mass scanning tunnels, our MOT stations, and all our integration with WMS, ERP, or e-commerce systems.

“Understanding RFID and RAIN is key to understanding what we do at Clustag: automating intelligently, optimising with precision, and providing real visibility into the flow of millions of products each day. From there, everything we do makes sense.”

That leads us nicely into Clustag. Tell us a bit more about the company.

“Clustag is much more than an RFID solutions provider. We design, manufacture, install, and support customised RFID solutions for all types of warehouses: from manual operations to highly automated centres.

“We are a global company specialising in advanced RFID and IoT solutions applied to intralogistics, traceability, and process digitalisation. Our main headquarters is in Valencia, Spain, and we have a direct presence in North America, with offices in Miami (where I spend most of my time) and a subsidiary in Puebla, Mexico. We currently operate in over 30 countries and have deployed more than 3,000 active RFID solutions.”

What is the Clustag point of difference?

“All our RFID solutions incorporate Zentup, our exclusive middleware that seamlessly integrates hardware and software, enabling total and secure control over data capture and management. This integration ensures that all collected information is accurate, reliable, and available in real time for decision-making.

“In addition, we have patented technology, RFID-Shield Technology, which prevents any kind of cross or unwanted reading between boxes – stray reading – even in the smallest spaces. This guarantees the highest precision in the identification and traceability of each item, eliminating errors and improving operational efficiency. Thanks to these innovations, our clients benefit from faster, safer processes with complete visibility over their inventory.”

And all this happens with a 100% focus on real integration with the client’s systems such as their ERP and WMS.

“Since day one, we have been committed to innovating where it matters most: precision, speed, and visibility. Today, our systems have processed more than five billion RFID tags and have achieved reliability levels above 99%.”

What does this precision, speed and visibility mean for the client?

“It means the ability to make decisions in real-time. Thanks to Zentup, our customers can see exactly the status of every item at every point in their operation.

“It also enables seamless integration of both hardware and software. Our implementations are agile and functional, designed to minimise any disruption and to ensure that daily operations continue smoothly without unnecessary interruptions.”

Could you talk us through some real-world examples of Clustag’s success with clients?

“At Clustag, we don’t make promises. We deliver results and provide tangible, sustainable outcomes in any sector. We minimise errors and inventory losses through automation, offer total real-time visibility for agile decision-making, ensure seamless integration with existing systems without disrupting operations, and optimise every logistical process, from inventory management to order fulfilment.

“All of this is achieved under strict security standards and regulatory compliance, resulting in cost savings, improved customer experience, and a true competitive advantage. Let’s start with an example from the retail fashion sector, with Sport Time, which distributes Nike products in some territories of Eastern Europe.

“To address the logistical challenges of sports distribution, Sport Time Group implemented Clustag’s parcel RFID Solution (MOT Station), powered by RFID-Shield Technology and Zentup, an advanced system that optimises post-picking control in its distribution centres.

“Post-picking RFID control: The MOT S20 scans items at order level as they are grouped into boxes, automatically detecting if any products are missing, if there are unexpected items, or unreadable tags.”

Automated audit: Boxes with discrepancies are diverted to an audit area, where operators use Zentup software to correct errors before shipping.

Full integration: The system connects Sport Time’s warehouse systems, enabling efficient inventory management and order preparation, even with multiple materials and references.

Results: There has been a significant improvement in order accuracy, a reduction in human errors, and greater speed and reliability in preparation for retail, wholesale, and e-commerce.

“Thanks to staff training and familiarisation with Zentup, Sport Time has optimised inventory management and raised the standard of efficiency in sports goods distribution in Eastern Europe.”

Our second example comes from the pharma and healthcare sector, focused on loan kits.

“In the rapidly evolving field of healthcare logistics, precision is essential. A major global pharmaceutical company faced significant challenges managing orthopaedic loan kits, which were often packed manually, shipped to hospitals, returned incomplete, and processed again, all while needing to maintain flexibility, inventory accuracy and proper billing.”

To address these issues, the company sought to establish a robust quality checkpoint system at every stage of the kit’s journey:

Outbound: kits scanned before leaving the warehouse.
Hospital arrival: contents verified upon delivery.
Return: kits scanned before being shipped back.
Warehouse inbound: returned kits scanned to detect missing or incorrect items.

“If discrepancies arose, the system would need to flag them immediately, and any unreadable tags would need to be reprinted on the spot, eliminating delays and blind spots. This was crucial, as every missed tag could result in stock errors, surgical delays, or billing disputes. The company required a solution that would provide clarity, speed, and total control over a complex, high-volume process.

“The successful solution was provided by Clustag’s Standard RFID Solution (Massive Plus Station), powered by RFID-Shield Technology and Zentup, turning a manual, error-prone process into a streamlined, intelligent workflow. The solution delivered speed, accuracy, and traceability, proving that RFID can thrive even in non-automated environments.”

The future looks exciting. What’s next for Clustag?

“At Clustag, on a global level, we aim to be the global leaders in intelligent traceability solutions and advanced asset management.

“Under my leadership as North America Director, we are fully committed to innovation and to tackling every challenge our clients present to us, whether in pharma, food, fashion, or sports. Our ambition is to continue growing, launch new projects in more US states, and strengthen our presence throughout the country.

“We will be present at MODEX 2026 in Atlanta, after recently participating at Promat Chicago. We are determined to stay at the forefront, wherever the future of logistics is being shaped.

“But our real driving force is our ability to adapt and anticipate the needs of such diverse industries. At Clustag, we don’t just install technology, we transform operations, support our clients, and turn every challenge into an opportunity to innovate and grow together.

“Because being a leader means knowing where to go, why to go there, and having the determination to bring others along on the journey.”

The post Asset Tracking with RFID appeared first on Logistics Business.

Bringing together the advantages of RFID Auto ID and in-mould labelling, Inotec’s RFID Inmould Labels offer durability, accuracy and sustainability. Developed in-house and tested in live customer applications, they are already helping leading logistics and packaging companies move away from single-use plastics while gaining full transparency across their supply chains.

Smart tray tracking at scale

A recent collaboration with EPT (Euro Plant Tray) demonstrates the real-world benefits of this solution. In the plant wholesale sector, over 95% of trays are currently single-use, contributing to around 40,000 tonnes of discarded plastic waste each year in Europe alone. EPT sought a reusable alternative that could deliver both environmental gains and digital traceability.

Working with EPT, Inotec developed a customised RFID inmould label that is seamlessly bonded to the reusable tray during injection moulding. This label offers exceptional durability – it is flush with the surface, waterproof, UV-resistant, and resistant to cleaning chemicals and mechanical impacts. Despite its compact size, it delivers a high-performance read range and allows bulk scanning of up to 1,000 trays simultaneously, with no line-of-sight required.

EPT’s trays now feature a secure, embedded RFID label that supports real-time tracking, inventory management, and cross-border reuse. The RFID inmould label is helping EPT reduce waste, optimise its processes, and set a new European standard for smart, reusable transport packaging.

Advanced performance, built to last Inotec’s RFID inmould labels are based on its own INO-TAG DIOBOND range and incorporate high-performance NXP RAIN RFID chips.

Key benefits include:

● High-speed scanning – multiple tags can be read simultaneously, even at distances of up to 15 metres
● No line-of-sight required – increasing speed and accuracy while reducing labour
● Secure, high-capacity data storage – with the ability to store encrypted tracking and logistics data
● Extremely durable – scratch-proof, smear-proof, waterproof and resistant to chemicals and temperature fluctuations
● Fully recyclable – made from the same material as the container for easier recycling
● Reduced energy use – thanks to in-mould’s one-step automated production process

Ideal for regulated and high-compliance sectors RFID inmould labels are particularly suited to industries where hygiene, traceability and security are critical. In food and pharmaceuticals, the edgeless bond eliminates contamination risk and withstands freezing, washing and sterilisation. IML is also compliant with strict FDA regulations and prevents label tampering or counterfeiting, which is critical for protecting intellectual property and public health.

“With RFID Inmould Labels, we’re combining durability, traceability and environmental responsibility in one powerful solution,” says David Stocker, General Manager at Inotec. “As seen with EPT, this technology helps our customers meet growing regulatory demands, streamline their processes and take a major step towards a circular economy.”

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As with most ecommerce businesses the speed and efficiency of the pick, pack and dispatch operation is vital, making all the difference to customer satisfaction levels and potential sales – particularly, at peak. For the managing director of UK Planet Tools, Bohdan Hrystayenko, this was an aspect of the business where he could see automation bringing significant cost savings combined with an uplift to productivity and it was the packing operation that held the greatest potential for a fast return on investment (ROI).

Labour savings

Having spoken with Sparck Technologies, Hrystayenko was aware of the major benefits, in the form of labour and materials savings, that could come from using automated ‘right-size’ boxing technology. Sparck Technologies’ CVP Impack auto-boxing system has the capability to tailor-make up to 500 boxes per hour, for multiple or single item orders, using advanced 3D scanning technology to optimally size, create and label each parcel in one seamless process – reducing package volumes by up to 50%, cutting cardboard usage by 30% and eliminating the need for void fill.

The technology was perfect for UK Planet Tool’s varied product profiles and mixed order quantities. The CVP Impack was highly flexible, capable of scanning and making boxes to the exact size needed for single item orders or multiple items, time and time again.

Why wait?

“This machine was exactly what we wanted,” says Hrystayenko. “Even though our daily throughput was only about half the capacity capable of the CVP Impack we knew we could reap enormous benefits from installing the machine now, rather than waiting. We were confident that with this machine in place we would have the operational flexibility and extra capacity to grow, without any fears over hitting peak volumes or trying to find additional labour. It was the right thing to do.”

An order for a CVP Impack was placed at the beginning of November 2024 and installed on 17th December, with ‘right-size’ packages rolling off the machine just two days later. “Space in the warehouse was tight but with some creative thinking from ourselves and Sparck we made it work. It was an incredible feat, supplying and installing the whole system in just eight weeks,” he says.

Big benefits

“The benefits for our business have been enormous,” says Hrystayenko. “With each box now custom-made to fit the exact dimensions of every order, we’ve eliminated the waste of shipping empty space. This alone has saved us 40% on consumables and material costs. Our reliance on manual labour has dropped significantly, transforming what was once a labour-intensive packing process. Like many ecommerce businesses, Mondays are our busiest days. Previously, we had to start early to clear the weekend backlog, but now we don’t begin until 8am. Thanks to the CVP Impack, just two operators can manage 250–300 packages per hour, removing the need for overtime and extra staffing.”

But for Hrystayenko, the most significant benefit from purchasing the Sparck’s CVP Impack has been the uplift in customer service, enabling a 5pm cut-off for a next-day delivery – a reliable fulfilment capability that builds customer confidence and wins new business. “The Trustpilot reviews have been glowing green ever since,” says Hrystayenko. “In fact, I calculate that had we installed the CVP Impack before the autumn peak we could have done 1.5x the business we did. This machine has given us the opportunity to grow the business. There’s no stopping us now.”

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The post Right-sizing for Growth appeared first on Logistics Business.

A smarter, reusable solution

Unlike standard sticky labels, Drytack features a unique dry acrylic adhesive that clings securely to smooth surfaces without leaving any residue. It can be applied and removed by hand – and reused repeatedly. Even if the back gets dusty or dirty a quick wipe with a damp cloth restores the adhesive qualities, making it ready to go again.

Drytack offers all the benefits of magnetic labels – such as flexibility and repositioning – without the cost or bulk. It’s a polyester label with a dry-tack adhesive backing, ideal for dynamic warehouse environments where stock and storage configurations change frequently.

Tried and tested in Europe

One of Germany’s largest bicycle manufacturers recently turned to Drytack when launching a new warehouse with 30,000 racking spaces. Ahead of the full warehouse rollout, the company needed to temporarily mark 5,000 locations as ‘blocked’ and sought a solution that was simple, visible, and easy to reverse when required.

Drytack labels were used to cover existing barcodes, clearly indicating inactive locations while avoiding errors during scanning. Staff could see at a glance which areas were off-limits – and when a location needed to be reactivated, the label could be peeled off in seconds, leaving no trace behind. The customer praised the solution for its simplicity, efficiency, and sustainability.

“With Drytack, Inotec gave us an easy yet highly effective way to label blocked shelf spaces. The handling is straightforward, and the reusability makes it a more sustainable choice,” said the Production Manager of the Bicycle Manufacturer.

Why it matters

Drytack is perfect for operations where shelf or pick locations change frequently, such as seasonal stock rotations. A good example is footwear retailers who shift from flip-flops to winter boots as the seasons change. Drytack makes it easy to relabel quickly, without investing in expensive magnetic alternatives or damaging existing racking with adhesive residue. Available blank, pre-printed, or as thermal transfer-compatible material, Drytack suits a wide range of applications across warehouse, logistics, and retail environments.

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Coesia, head-quartered in Bologna, are perhaps a well-kept secret in the ecommerce and logistics sector, being a much bigger company than perhaps people realise, with 8000 staff, 20 companies, 87 manufacturing plants and a turnover of €2 billion. What readers will be interested in is what the company does in terms of wrapping, palletizing, robotics, carton boxing and end-of-line, fulfilment products. I asked Fabrizio Sasdelli, E-Commerce Business Line Director, about the different brands and divisions.

Fabrizio Sasdelli: As you mentioned, Coesia includes more than 20 companies, grouped into three main divisions. The Regulated Markets Solutions (RMS) division covers areas like packaging systems. The Consumer Market Solutions (CMS) division focuses on products typically found in a supermarket, such as powders, liquids and solids. The Industrial Market Solutions (IMS) division handles automation and includes companies brought together for strategic synergies.

Our aim is to combine expertise across industrial automation, software and process engineering. We have a strong engineering core and a central division that supports all group companies in accelerating solution development, including tools like digital twins for project evaluation. What sets Coesia apart is our ability to integrate specialised know-how across the group. The collaboration between companies acts as a shared platform, enabling the creation of customised and scalable solutions.

We provide packaging systems within fulfilment workflows, while also developing finished products. Our technologies support right-size packaging and efficient shipment composition, which help reduce environmental impact. The result is a smoother process, faster response times and high operational reliability. With our global footprint, we ensure continuous support to customers around the world.

Logistics Business (LB): What are the key product developments?

Sasdelli: We have two big groups: packaging-on-demand, and automation. When required we can also integrate the two. In terms of solutions, this includes carton packaging, box resizing, digital printing on demand, and printing in the box. Then we have all the robotics: palletising, robot picking, and AMRs, plus conveying systems, where we are very strong, and vertical sorters. Right-size boxing means that we do not have standard boxes, but we can customise size, based on random products, creating the right parcel.

LB: I want to go in detail about the Emmeci business and the fit-to-size carton machines.

Sasdelli: Yes, Emmeci offers a range of fit-to-size machines. For example, we can produce custom-sized American boxes that adapt to different product dimensions, from small items up to larger parcels. Each box can be individually adjusted, using data from the warehouse management system (WMS). The system supports both automatic and manual box definition, and the packaging process begins as soon as the product arrives.

The E-BFS is ideal for single or multi-item orders. It creates right-sized clamshell boxes, integrating box making, filling, sealing and labelling. It also supports personalisation, including printed invoices or marketing inserts, based on customer data. Return handling can be built into the design as well. The E-SWL produces right-sized paper bags in various formats. It includes an automated carton erector for minimal manual intervention and precise adjustment of box height. We also offer the Autobagger, a compact modular machine for shipping bags. It fits easily into existing operations and can run up to 1,200 boxes per minute, or less, depending on requirements.

We also provide a vertical bagger and a wide portfolio to cover diverse packaging needs. Few competitors can match this breadth. Our systems are highly customisable and scalable, with options for both automated and semi-automated setups. We tailor our solutions to match different warehouse configurations and customer workflows.

LB: You mentioned a few other products which we can talk about, such as Flexlink’s conveyors, palletizers, robotics, sorters, AMRs as well?

Sasdelli: Flexlink manages all the automation, which affects everything. It is very strong and is used to working with other group companies, connecting different machines and providing direction.

LB: Palletising, particularly robotic palletising, is very much in vogue now, isn’t it? A lot of companies are partnering and automating that part of the outbound process. What palletizer machines do you have? What is it that Coesia manufactures? Everything including the robotic arm? Or are you buying that from a supplier?

Sasdelli: We recognise the growing demand for robotic palletising. At Coesia, our company FlexLink offers smart, space-saving and easy-to-integrate solutions for both inbound and outbound operations. One of our key offerings is the RC12 collaborative palletiser, now in its third generation. It is ideal for end-of-line processes where space is limited, as it uses more than 50 percent less floor space compared to standard industrial robots. It is also very user-friendly. Operators can create pallet patterns without needing any programming skills, thanks to the intuitive software.

The RC12 can handle up to 14 boxes per minute using a double gripper. It meets international safety standards for collaborative robots and works safely without cages or barriers. For larger and faster operations, we also offer the RI20 industrial palletiser. This solution is designed for continuous use and delivers high throughput with great precision.

We also focus on software and system intelligence. Our in-house algorithms manage different box sizes efficiently. For example, we can use scanners to detect incoming boxes, buffer them, and then optimise pallet building. The system ensures fast operation, stable pallet formation and maximum volume use, even when box sizes vary by just a few millimetres. We are flexible when it comes to robotic arms. The RC12 integrates an Omron arm, but we can work with whichever brand the customer prefers. What matters most is providing a reliable and efficient palletising system that fits the customer’s needs.

LB: In terms of right size packaging, not wasting or shipping air has been a trend in recent years. We see this with companies that we report on in the sector like Spark and CMC. Bottom line, what kind of savings have you been able to make customers in recent years with e-commerce in terms of the right size packaging and reducing the amount of packaging waste, space and void in the final package?

Sasdelli: It depends on the application. There are cases where we used to have a standard size, where we have seen a lot of cases where they put inside 1:10 and 1:00. Just one book and 99% of the volume is fully empty! Like this we can save packaging by using the right size that can help in this way. When you are used to having a standard box and you have volumes that can change a lot, I think that you can really save a huge amount.

LB: Sustainability and automation. What would you say would be another big issue that you’re focusing on with customers?

Sasdelli: Sustainability is a major focus for us. We’re investing significant resources into programmes that directly influence the design and efficiency of our machines. We help customers reduce energy and material consumption, and our solutions often include tailored automation that meets specific sustainability goals.

Another key strength is our engineering capability. The Coesia group has built deep synergies across its companies, which allows us to offer flexible and highly customised solutions. We also have a strong environmental certification department that supports customers with compliance and optimisation. Ultimately, our aim is to design systems that reduce waste, minimise packaging volume and lower the overall environmental impact.

LB: I was talking to Jo Bradley at Spark Technologies about a year ago and I asked what’s your biggest competition? Expecting her to name other companies, she said actually, it’s the unavailability of manual labour. Lots of customers are buying automated packaging machines because they simply cannot get the staff to do the manual process. So most of their wins are actually replacing manual operations, rather than directly going head-to-head with another automation supplier. Do you find the same in most of your markets now?

Sasdelli: Yes, we see that trend in many markets, especially in Germany. Finding skilled labour is becoming increasingly difficult, particularly during peak periods or when companies scale quickly. Automation becomes the only practical solution to maintain efficiency and reliability. It’s not just about reducing manual effort, but also about ensuring consistent performance where labour simply isn’t available.

LB: Are there any typical packaging products that you don’t manufacture yourselves? I’m thinking of stretch wrap or shrink-wrapping machines, do you do you provide those as well or do you buy those in?

Sasdelli: In most cases, we can provide what the customer needs. When specific packaging products like stretch or shrink-wrapping machines are not part of our standard portfolio, we collaborate with trusted suppliers. We are always open to integration partnerships to deliver a complete solution. FlexLink, part of the Coesia group, has over 40 years of experience as a systems integrator. They are experts in designing complex automation setups and often work alongside both internal companies and external partners, including market companions. This flexibility allows us to choose the best technology for each project and ensure it fits the customer’s requirements perfectly.

LB: What would be the largest scale e-commerce projects that you’ve worked on recently, in terms of the implementation, number of machines or facilities?

Sasdelli: In our largest e-commerce projects, we typically combine two or three core machines with a full automation setup. End-of-line palletizing is almost always included. One of our key strengths is delivering both the packaging systems and the automation that connects everything into a complete solution. Depending on the project, we might integrate labelling units, palletizers, and robotic or manual workstations. For larger operations, we have deployed up to ten robots. We also create a digital twin of the entire system, allowing us to fine-tune performance together with the customer and ensure the solution is exactly right.

LB: You’re using a lot of simulation while you’re consulting for projects?

Sasdelli: Yes, we have dedicated staff who support simulation activities and can assist in creating complete models for each project. It is not just about visualising the flow, dimensions or footprint, but also about accurately sizing the system’s capacity. This includes determining how many workstations are needed to handle different scenarios. We evaluate various possibilities, verify the most effective solution and design the integration accordingly.

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The joint solution, which connects Loftware Cloud with SATO’s cloud-connected printers, eliminates printer driver dependencies, allowing IT teams to avoid installation, troubleshooting, updates, and management. This significantly reduces maintenance and support costs, while enabling businesses to print from any PC browser, providing flexibility to scale or adapt operations without technical constraints. Additionally, users can access the latest approved label templates from anywhere, at any time, through a secure browser and seamlessly print from their SATO printer. The platform also streamlines user management, enabling administrators to quickly add and approve new users in minutes without the need for license keys, reducing administrative burden and improving operational efficiency.

The Loftware/SATO partnership supports a range of industry applications. This includes supplier compliance to ensure accurate, timely labeling and RFID tagging – eliminating relabelling and improving supply chain efficiency. It also enhances in-plant labelling for better process control within factories, ensures retail labelling consistency with industry standards, and streamlines third-party logistics (3PL) labelling for seamless integration with logistics providers.

Hayato Shindo, Group Business Officer at SATO Corporation, commented: “In today’s fast-paced business environment, manufacturers face many challenges, such as changing customer, legal and regulatory requirements; remote working and collaboration; rapid scaling up of operations; and improving productivity while reducing operating costs. Traditional desktop label design applications, while effective in the past, are no longer sufficient to manage these complexities. The solution provided by SATO and Loftware addresses these challenges head-on by offering a centralized and secure platform for label design and printing.”

Loftware Cloud expands labelling capabilities across internal stakeholders, external suppliers, co-manufacturers, and co-packers, who all play a role in the complex supply chain process. With seamless integration into both on-premise and cloud-based business applications such as ERP, WMS, and PLM, Loftware Cloud optimizes workflows for greater efficiency and accuracy.

SATO’s cloud-connected printers further enhance this solution with effortless installation and mobility. Simply connecting a LAN cable ensures the printer is ready for immediate use. This plug-and-play functionality makes it easy to relocate printers as needed, giving businesses the flexibility to adapt to changing operational demands.

Denis Stojanoski, Loftware Senior Alliance Program Manager, added: “Loftware and SATO have a long-standing partnership built on a shared commitment to innovation. Together, we continue to develop cutting-edge supply chain solutions that empower businesses to operate more efficiently, adapt to evolving industry demands, and future-proof their operations. By combining our expertise, we’re driving the future of labeling to deliver greater agility, scalability, and value for our customers.”

Loftware and SATO’s global partnership extends over a quarter century. In recent years, the two have developed an advanced RFID encoding and logging solution to help businesses meet stringent traceability standards. The partnership between Loftware and SATO represents a strategic shift toward addressing specific use cases to better meet modern business needs.

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“Amazon-style returns for D2C brands,” is what ReturnBear’s CEO, Sylvia Ng (pictured, below), told me her company can offer when we met at Manifest Las Vegas. International ecommerce returns management is the forte and niche of the Canadian company she leads. “Some buyers know they will return items when they buy them,” she states.

Returns rates in the D2C brand sector average a whopping 35%, with clothing and fashion being the largest sector for returns by far. “Electronics, home goods, and beauty products tend to have high return rates,” Ng adds. “Electronic goods often face issues with buyer’s remorse or compatibility concerns, while homeware goods like furniture can suffer from size mismatches.”

Returns cause inevitable supply chain headaches, but how can they be ameliorated? As a 4PL (fourth party logistics operator) ReturnBear, based in Toronto, work with brands to lessen the costs and complications of returned, unwanted goods. In 2024, ReturnBear surpassed the 1 million returns milestone, processing over 1 million returns through its end-to-end system, which includes a returns portal and automation software.

“Merchants face high costs and returns take too long,” says Ng, adding that sustainability issues also press brands and retailers to lessen the, often, long load back. When a consumer wants to return one item or more and be refunded a retailer merchant first has to provide them with a shipping address label. Ideally, the consumer should get an instant refund but do the first mile of the return journey – namely to take the re-packaged parcel(s) to a returns centre.

Keeping it Local

If a brand merchant sells in multiple countries ReturnBear keeps the products local. The company has such a facility near us, in Milton Keynes, Buckinghamshire, that receives all British returned items and keeps them in the UK for re-despatching. When the item(s) are received back at the returns centre they can be checked, inspected and re-packaged or tagged ready for delivery to the next customer, without going all the way back to the retailer’s warehouse or factory, which is usually far from the consumer and often in a different country.

“Merchants can easily sell in a hundred countries overnight using global selling platforms,” Ng tells me, “but there is no easy way to get returns back. Our expansion into the UK market is part of our vision to be the first global end-to-end platform for single-day returns. The new MK facility is run in partnership with Reship and the expansion coincides with us extending our support to clients.” By entering the UK market, ReturnBear can now offer a suite of reverse logistics solutions to enable merchant retailers to provide good experiences without a direct local presence.

“Cross-border eCommerce continues to outpace domestic growth, driven by increasing consumer confidence in international shopping and the expansion of global fulfilment networks,” Ng says. “However, challenges like returns, duties, tariffs, and logistics complexities remain key pain points – ones that we help brands navigate.” There is a need to streamline returns processes and improve customer experience.

ReturnBear offer merchants package-free and label-free convenient return points as an alternative to returning items by post. The company claims that as much as half of return logistics costs can be saved by this method. There are over 1000 such return drop-off points in Canada, covering 80% of the population there. “While Canada is our primary operational base, we operate in the US, UK and Australia with dedicated returns warehouses that help merchants receive, verify, and process returns. Where applicable we forward fulfil the returned inventory to local customers, preventing the need for merchants to ship product back to centralized warehouses that are typically across borders or oceans. With this service we reduce the distance travelled by returns by 40% and therefore reduce emissions by the same amount. We’re seeing strong demand in the US, UK, and Australia for this service which is very aligned with our strategic expansion.”

Stopping Fraud

Cross border returns, with pre-clearance, commercial invoices and shipping manifests are provided. What about bulk shipments? “Our batch consolidation model allows brands to reduce the cost and environmental impact of returns by grouping multiple returned items together before they are shipped back to a warehouse or resale location. Instead of processing individual return shipments, items are collected at regional hubs and shipped in bulk – lowering logistics costs, reducing carbon footprint, and improving efficiency.”

“Fraud prevention is important, so we verify that the correct item has been returned if a refund has been actioned by the scanning of the returns shipping label,” Ng explains. “Merchants can easily sell in a hundred countries overnight using global selling platforms. But there is no easy way to get returns back. Our expansion into the UK market is part of our vision to be the first global end-to-end platform for single-day returns,” she added. “Consumers check for convenient returns before buying, and merchants must meet consumers’ expectations to grow in local markets. ReturnBear provides a simple way to do that.” And we all must keep the consumer happy, right?

The post When the Consumer Says ‘Return’ appeared first on Logistics Business.