Less time in the process: faster packing without compromising on quality

Time is a valuable asset in any packaging process. Whether you’re packing by hand or using automated lines, every second counts. Inefficiencies such as awkward packaging materials, poorly organised workstations or outdated equipment can cause delays, mistakes, and increased labour costs. That’s why at Topa, we look not only at the packaging itself, but also at the entire working environment around it.

‘Less time in the process’ is one of the seven key focus areas through which we help organisations reduce the Total Cost of Packaging (TCP) in a structural way. By optimising packaging and processes, you save labour time and boost productivity, all without sacrificing quality.

Where is time being lost?

Time loss in the packaging process can occur in various ways. For instance, packaging that’s difficult to open or close causes delays at the packing table. A lack of standardisation may force staff to repeatedly figure out the right method of packing. And the absence of ergonomic workspaces can lead to fatigue and a slower pace.

By taking a critical look at the workflow, materials used and layout of workstations, we can identify and resolve inefficiencies.

How to save time

We always begin with an analysis of the current situation: where are the bottlenecks, which actions take unnecessarily long, and how well is the packaging process aligned with the rest of your logistics? Sometimes, the solution lies in something simple, like boxes that are quicker to assemble, easier-to-use tape, or packaging that better fits the product and the workflow. Many of these solutions are readily available from our existing product range and can make a noticeable difference straight away.

If more is needed, we’ll work together to develop a bespoke solution. For example, a pack that can be closed in one movement, reduces the number of actions required, or cleverly combines with the right type of void fill. In doing so, we look beyond the packaging itself and focus on how it’s handled, with as few steps and interruptions as possible.

The workstation also plays a crucial role. A well-organised packing table can make the difference between a chaotic and a smooth process. We supply packing stations in various configurations, from compact and basic to fully customised to suit your product, your warehouse, and even your employees. Adjustable height, integrated void-fill systems, and logical material placement all contribute to better visibility, fewer movements, and a more comfortable working pace.

In practice: more clarity and speed at Accell

For Accell, a manufacturer of bicycles and bike parts, we reviewed the packaging process. The existing approach was partly manual and placed high demands on staff within limited timeframes. Together with Accell, we analysed the goods flow and activities at the packing stations.

Based on this, we delivered a custom-built packing line, including ergonomic workstations and intelligent packaging solutions. These included made-to-measure packing tables, tailored not only to the specific product type but also to the people working with them. Materials are now within easy reach, work height is adjustable, and unnecessary movements have been eliminated.

The result? Fewer actions per package, a lower error rate, and higher output per employee. Just as important: staff reported a more pleasant and consistent working experience, which contributes to continuity and job satisfaction.

Read the customer case: Accell.

Curious how you could save time in your own packaging process?

We’re happy to help you explore the options. A well-thought-out solution isn’t just faster, it also creates more calm, fewer errors, and a better working rhythm. Because less time in the process doesn’t mean less attention, it means greater control over efficiency and continuity. Feel free to contact us on +31 252 245 200 or: info@topa.nl.