Coveris Doubles Folder-Gluer Output with Three Additional Ergosa Universal Packing Solutions

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At IMPACK Packaging Equipment, we take immense pride in helping businesses enhance their productivity and efficiency with our innovative packaging solutions. Coveris, a leading European packaging company, is an example of how our machinery has increased output.  

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Investing in Ergosa C: A Game-Changing Decision 

In 2017, Coveris Flexibles UK Ltd in Wisbech made a pivotal decision that would transform their packaging operations. They invested in an Ergosa C, a Universal Packing System, complemented by a Perpack Module with IN2A Box Turner. Since the Ergosa C is compatible with any box type, it offered the flexibility, speed, and efficiency Coveris needed to keep pace with their demanding industry. 

 Trevor Storr, Site Manager at Wisbech, explains what convinced Coveris to invest in IMPACK solutions.  

“Our decision to use an Impack Solution was influenced by its reputation for reliability, advanced features, and positive reviews within the industry. The comprehensive support and customisation options provided by Impack also played a crucial role in our decision-making process.” 

Building on Success in 2022

The success of the initial investment was so significant that Coveris decided to further optimize their productions in early 2022. They added three additional Ergosa C packers with IN2 Box Turners, with two installed at the Wisbech site and the third at the St Neots site. This expansion is a testament to the value that IMPACK solutions brought to Coveris' packaging operations. 

Workflow Optimization and Labor Reallocation

One of the key benefits of implementing the Ergosa C machines was the optimization of packing processes and enhancement of overall operations. Storr explains: 

“While staffing challenges were not the primary factor, the Ergosa C machines offered a strategic solution to optimise our packing processes, allowing us to maintain efficiency and productivity even during fluctuations in personnel availability. The implementation of Ergosa C machines has allowed us to reallocate some packing staff to other critical areas of production where their skills can be utilised more effectively. This strategic deployment has enhanced overall operational flexibility. The transition involved a careful assessment of our production workflow. Packing staff were redeployed based on their skills and expertise without compromising on any aspect of our production process”. 

The introduction of Ergosa C machines enabled Coveris to optimize labor without increasing costs. Streamlining processes and maximizing the capabilities of the existing workforce led to significant cost-efficiency gains. Storr adds:

 “The introduction of Ergosa C machines has enabled us to optimise labour utilisation without increasing costs. Although specific percentages may vary, we have achieved cost-efficiency by streamlining processes and maximising the capabilities of our existing workforce”. 

 

 

Dramatic Increase in Production Output

The impact of Ergosa C machines on production output was nothing short of remarkable. Coveris saw a doubling of their production output, translating to a substantial increase in boxes per minute. Automating just the packing process had a significant impact on the entire production increasing overall capabilities by 10%.  

 

 “The doubling of our production output translates to a significant increase in boxes per minute, showcasing the substantial impact of Ergosa C machines on our overall manufacturing capacity. The exact figures depend on the product type going through the machine at that time.” 

~Trevor Storr, Site Manager, Wisbech 

Storr explains how doubling folder-gluer output positively impacts the entire production:

 “The folder-gluer speeds and packing speed gains achieved with Ergosa C machines have demonstrated a substantial increase in efficiency. While specific multiples may vary dependent on product type, the overall performance improvement has exceeded our expectations and contributed significantly to our enhanced operational capabilities in finishing by around 10% overall.” 

Coveris also benefited from the Perpack option, which reduced manual handling risks on thicker grade cartons, leading to improved KPIs in the finishing line and a faster flow of products through the site. 

 “This universal packing system has allowed the business to double its output on straight-line and crash-lock products without any increase in labour costs, creating a reduction in inventory and making the flow of our process a lot quicker leading to shorter lead-times and greater flexibility. Including the Perpack option onto one of the Ergosa’s has also been a big safety benefit to reduce manual handling risks on thicker grade cartons. The introduction of this has really benefitted the business by increasing KPIs in the finishing hall and leading to a faster flow of the product through the site”. 

Trevor Storr, Site Manager Wisbech 

Coveris' success story with IMPACK Packaging Equipment is a token of the transformative power of our solutions. We are thrilled to have played a vital role in helping them achieve remarkable efficiency gains and production improvements.

"Since the installation of the first Ergosa in 2017, Coveris has been a close partner for us. The recent acquisition of 3 additional machines stands as a clear testament to our close collaboration and highlights the significant production efficiencies they deliver”. 

John Hall, IMPACK UK Sales Agent, iPack Solutions 

As we continue to innovate and provide customized packaging solutions, we look forward to helping more businesses like Coveris reach new heights in productivity and success. 

About Coveris 

Coveris is a leading European packaging company that manufactures flexible and sustainable solutions for some of the world’s most respected brands. Operating across 30 plants throughout the EMEA region, developing packaging that protects all types of products from food to pet food, from medical devices to industrial and agricultural goods. 

 

 

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iPACK - Photography by Dave Thompson square

 

 

 

IMPACK is represented in UK by agent John Hall of iPack Solutions.

tonino dominici
"We can now better exploit the productivity of our folder gluer lines. Our folder-gluers can run at a faster rate and our team can produce more cartons in the same amount of time with less effort thanks to IMPACK."
Tonino Dominici
President at Box Marche, Italy
★★★★★
Nicolas Prévot
"First and foremost, we can say that it is more of a partnership than a customer-supplier relationship. IMPACK offered us custom-built solutions that were really tailored to the complexity of our products – something a lot of other companies were unable to do."
Nicolas Prévot
Head of Maintenance at DS Smith, France
★★★★★
Remco Maandag
"Where we used to pack with 2 people, we can do the same job with 1 packing person with IMPACK's Ergosa."
Remco Maandag
Owner at Van Grasdorff, Belgium
★★★★★
 

CONSIDERING WORKING WITH IMPACK?

 

Book an appointment with an IMPACK Expert. Service starts with our first meeting. Our production analysis helps you to identify your bottlenecks and shows you how you can double your production speed, increase your output, and redeploy your packing staff to more valuable positions.

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