Mailer Line Case Study
A mailer envelope production line that produces a ‘ready to ship’ envelope from a roll of paper or plastic film as the outer shell and a roll of bubble as the inner protective shell. The substrates are adhered together, folded, sealed and cut to length; resulting in a staged finished envelope ready for box loading.
- Finished mailer line exceeded customer expectation for both versatility and speed.
- Line speeds of 100 ft/min, which averages to about 400 #000’s and about 75 #7’s per minute, as compared to competitors speed of20—80 pieces per minute.
- Mailer production line can run both paper and plastic film (a unique feature in this industry).
- Quick turn-around from concept meeting (January 2016) to delivery and installation (July 2016).
- Customer was able to brainstorm with Priority Machine during the production phase to create mid-production enhancements, allowing for maximization of output and increased customer satisfaction.
- Weekly updates, including photographs, sent to the customer provided collateral for upper management to share with their field sales teams, producing excitement throughout the organization as well as increased sales (prior to installation, the customer saw sales increase by 100,000 units based on the anticipation and confidence of the sales team).
- Production speeds and envelope size versatility superior to any mailer line currently on the market
- Incorporate state-of-the-art automation to reduce the number of operators needed to run the line.
- Ability to work with Priority Machine during design and production stages to ensure user interface and safety elements are aligned with their current production machines.
Priority Machine's Proposal:
- Allows them to be more competitive in the production of mailer envelopes and positions them as a leader in the growing online sales industry.
- With the addition of plastic film envelope production, they have become fully integrated in the product offerings to their customers; saving both money and time (vs. buying plastic film envelopes externally).
- Reduced labor cost to run the mailer line and increase revenue through line speed and efficiency.
- All user interfaces were programmed using their existing models, thus ramp up from installation to production was quick.
video:
- Custom design and fabricate a nine-machine production line integrating Rockwell Automation.
- Design and program line to produce envelope sizes ranging from #000 to #7 (4”x8”-14 ¼”-20”) with the ability to run single or double envelopes in parallel to produce high output.
- Ongoing communication and opportunity for site visits during all phases, including assistance with installation and set-up of the line.