Clothes warehouse integrates automated box cutting

Ralawise began investigating ways it could reduce the use of knives on its warehouse floor without reducing throughput.

Its cartons are often secured with nylon branding and wrapped with multiple layers of stretch film. To process these cartons effectively, Ralawise employs a team of warehouse operatives to cut, unwrap and unpack these boxes quickly, before moving them onto the next part of the distribution process.  

Steps were already taken to enhance the safety of workers, by using retractable blades and investing in high quality utility knives. However, while workers are always encouraged to exercise caution — and would have been provided with the appropriate training to use this equipment — using a blade manually always runs a risk of injury.

Instead, Ralawise began searching for an automated solution for box opening. It approached TM Robotics, a distributor of Toshiba Machine industrial robots. It suggested the Intelligent Box Opening Device (IBOD) – a case cutting and extraction machine from CASI, a specialist machine builder of automation systems for fulfilment processes. The IBOD is a specially designed, pass-through box opener. Using built-in intelligence, the machine can measure the size of every incoming case to find the programmed cut lines on each carton. As the machine is automatically self-feeding and self-aligning, using a conveyor, it does not require a human worker to tamper with boxes or blades.

However, switching from manual box opening to an automated version can be a significant shift for a distribution facility. From integrating the machine with existing technology, to preparing for the cultural expectations of employees of the factory floor, there’s a lot to consider. Before making the investment, Ralawise was invited to visit the CASI facility in Frisco, Texas to see the machine in action.

Gary Clibery, facilities and projects manager at Ralawise says: “One of the unexpected advantages was the reduction in damage to products. Aside from accidents and injuries, manual box cutting also runs the risk of damaging a carton’s contents, rendering the goods unsalable. Due to the automated nature of the machine, boxes are opened in a precise and controlled manner, reducing the possibility of accidental damage.”

Since the installation of the IBOD, Ralawise has cut 135,000 boxes at its Flintshire facility. Of these, only one box suffered from damaged contents — a considerable reduction compared to the damage caused by manual box opening.

The IBOD comes in two variations, to suit varying types of warehousing applications. The IBOD ONE, the smaller of the two models, can cut the top cases of cartons at a rate of up to 450 cartons per hour, whereas the IBOD DUO can operate at a rate of 750 cartons per hour. Ralawise choose the IBOD ONE for use in its box opening processes. 

Ralawise required the robot to remove lids from cartons entering its distribution centre. By automating this process with the IBOD, the company eliminated the possibility of cuts and strains, which are commonly associated with cutting boxes manually. However, the company also benefitted from increased productivity, due to the fast speeds of the IBOD. This automation also meant staff could work on more complex tasks, rather than simply opening boxes.

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