We began working with Pharmapacks in their first year of operation — and we have continued to work with them as they grow and encounter new challenges. For example, as order volumes increased, so did freight fees, damage rates, and labor costs. As their packaging technology partner, we helped them add, customize, and adapt packaging processes and systems to unlock much needed labor efficiency, keep costs at bay, and make the most of every square foot of their overwhelmed warehouse.
It was clear Pharmapacks needed automation to keep up with demand. As they expanded into their second facility, at 27,000 square feet, they introduced a SEALED AIR® brand I-Pack automated cartoning system, along with a tray erector. But demand continued to grow exponentially and the Pharmapacks team realized they hadn’t gone big enough — they were going to need an even larger facility.
A year later, Pharmapacks moved to Long Island, NY, and into their current 141,000-square-foot factory. They purchased and installed an additional six automated cartoning systems and five tray erectors. This allowed them to evolve from 22,000 packs per day in two shifts to 31,000 packs per day in one shift, with the ability to add shifts as they continue to grow.
“This new design has given us the capacity to grow, take on more business, expand into different territories, give a better customer experience — and that’s all from the automation,” says Andrew Vagenas, CEO of Pharmapacks. “Sealed Air was huge in this. We worked a lot with their teams and their engineers. This is what we came up with and they were critical in taking this live.”