Real solutions. Proven results.
Major Automative Manufacturer+ Automation Implementation in a Distribution Environment
The Challenge
A major automotive manufacturing customer, operating a 400,000 square foot parts distribution facility struggled with rising labor costs and throughput limitations as order volumes climbed. The facility handled thousands of SKUs ranging from small fasteners to bulky suspension components, many weighing over 40 pounds. Manual packaging processes—including case forming, lifting, sorting, bagging & sealing, and labeling—created ergonomic strain and contributed to a 22% year over year increase in minor injuries. Order accuracy hovered around 94%, and the facility frequently missed its same day shipping targets during peak demand. With overtime costs rising by 18% and turnover approaching 28%, leadership recognized the need for automation to support growing dealership parts demand.
Our Solution
Phoenix Packaging implemented an integrated packaging automation suite including automated case erectors, lift assist vacuum handlers, inline weigh and dimension systems, and automated print and apply labelers tied directly to the manufacturer’s ERP.
The Results
Within the first six months, packaging throughput increased by 38%, order accuracy improved to 99.2%, and packaging related injuries dropped by 41%. Labor savings totaled $1.3 million annually, largely from reduced overtime and improved workflow efficiency. Additionally, standardized packaging reduced freight variability, lowering shipping costs by 8%. The automation program not only improved worker safety and retention but also enabled the facility to absorb a 20% increase in order volume without expanding headcount, positioning the manufacturer for more scalable and resilient.
Major Industrial Distributor+ Transition From Steel to Poly Strapping
The Challenge
A major industrial distributor was using steel strapping, which required operators to manage sharp, rigid, heavy materials that frequently caused hand and eye injuries and demanded significant manual effort, as documented in industry examples where steel’s razor sharp edges and dangerous recoil created serious safety risks.
Our Solution
Phoenix Packaging worked with the distributor to replace their steel strapping with polyester strapping, which is lighter, more flexible, and easier to tension.
The Results
The customer’s operators experienced reduced physical strain and safer handling conditions. The transition also delivered substantial cost savings, as the polyester strapping eliminated the need for metal seals and reduced raw material costs by 30–50% due to its higher linear footage per weight. Additionally, woven polyester enabled one person operation and fewer coil changes compared to steel’s heavier, two person workflows, further reducing labor time and tooling expenses. Overall, the move to polyester strapping significantly improved workplace safety, enhanced ergonomic conditions, and reduced total cost of ownership.
Leading Pet Food Distributor+ Transition To Sustainable Coolers
The Challenge
A leading pet food distributor wanted to improve their customer experience and reduce environmental impact by replacing difficult to recycle polystyrene (EPS) coolers used to packaging pet food products. EPS disposal frustrations were a growing source of customer dissatisfaction, as traditional foam coolers are notoriously hard to recycle and always end up in landfills. Their large sizes make disposal challenging, particularly to customers in apartments.
Our Solution
Phoenix Packaging developed a 100% paper solution designed to efficiently replace their EPS coolers. The new paper coolers—made entirely from corrugated and layered paper insulation—were fully curbside recyclable and keep products at safe temperatures, meeting industry cold chain standards.
The Results
The distributor’s customers immediately reported a much-improved unboxing and disposal experience. Additionally, for every 10,000 paper coolers they shipped, they were able to prevent more than 6,500 cubic feet of EPS from entering landfills. Supported by a strong U.S. recycling infrastructure and a 93% paper recovery rate, the distributor also reduced waste handling costs and strengthened its sustainability credentials—all while maintaining reliable product protection.
