Efficiency is crucial in any warehouse, but even small challenges can lead to long, frequent, or expensive bottlenecks. Fortunately, the solutions to these inconveniences don’t require a major investment. Scale back on costs, prevent delays, boost team morale, and resolve common warehouse bottlenecks with better packaging solutions:

1.   Solve Tape Snafus with Tape Dispensers

Taping a fully packed carton is a cumbersome, often labor-intensive process that can create unforeseen delays, but you can streamline this with tape dispensers. Furnish each packing station with a tape gun as a fast and inexpensive solution, or install carton-taping machines. These devices use automatic conveyors to push the cartons through a tape station that seals with the top and bottom for maximum protection.

2.   Prevent Disorder with Labeling Systems

Some warehouses order carton labels from third-party vendors, but while this might seem like a convenient option, setbacks can occur when your warehouse orders too few labels or runs out. You might miss shipment dates as you wait for replacement labels. To avoid this, keep labeling machines near packing stations, so employees can print the correct labels as necessary. Since your team is familiar with your products, this will eliminate printing errors and label shortages. Plus, you’ll curb the waste of ordering labels in bulk.

3.   Avoid Waste with the Right Carton Sizes

It’s easy to lose track of the cartons your warehouse has in stock. Designate separate areas for each carton size, and ensure your receiving staff place the cartons in their right location. This will make it easier to deliver cartons to the packing stations for each production run. Familiarize your packing team with the carton sizes to use as well. From there, employees can adjust the carton forming machines as they alternate between products.

4.   Curb Obstacles with Mobile Exception Carts

When you have a short run, a clerical error, or a low stock of supplies, you might end up with incomplete orders. Stacking cartons from an incomplete order near the packaging line can cause obstacles that lead to warehouse safety issues. As an innovative and low-cost solution,  provide mobile carts for each line, so your team can use the carts to transport products to the staging area to clear the line and ultimately complete the run.

5.   Safeguard Pallets with Shrink Wrap Rolls

Even after a pallet is fully stacked with product, it’s still not ready for shipment. Your packaging team still has to secure the load onto the pallet, which often requires the use of shrink wrap. Stock rolls of wrap near each packaging station to secure the pallets quickly and prevent delays. Shrink wrap comes in numerous dimensions, so choose the best width for each product. This will ensure your team can maintain a seamless, efficient workflow.

6.   Reduce Forklift Loads with Pallet Jacks

A heavy industrial truck certification will ensure warehouse personnel are familiar with forklift requirements, but forklift operators won’t always be available when the packaging line finishes each pallet. In these scenarios, your packaging team will need to move pallets on their own, and that’s where pallet jacks come in. With accessible jacks, employees can pull finished pallets out of the way and continue packing the line to meet crucial deadlines.

A Smooth Workflow Starts with Packaging Solutions

Small issues can compound into significant delays over time at a warehouse. Implementing a few smart packaging solutions can eliminate many of these common bottlenecks while saving money and boosting customer satisfaction along the way.