Automated systems for parcel opening

The carton slides over the roller conveyor to the work table with clamping rails. Sensors scan the size. Several blades precisely cut the packaged goods, protected by safety mechanisms. This opening process succeeds without any problems, the contents remain untouched and are ready for further processing. To date, the German manufacturer ALS has developed 60 different opening systems. ROC 4flaps is the latest system from the parcel opening specialist.

Solution for international sporting goods manufacturer

The machine opens up to 400 parcels per hour. This is done chaotically - i.e. without pre-sorting. According to the supplier, this new system ensures that the goods in the box remain 100% intact when opened, as the blades do not come into contact with the goods. An international sporting goods manufacturer in Utha/USA wanted the efficiency of the parcel openers and, above all, the guaranteed integrity of all the goods. According to the customer's specifications, the opening system must not come into contact with the sportswear and shoe boxes on the inside when the boxes are automatically cut open in order to prevent damage and possible scratches to the sales boxes. Roc 4flaps meets these requirements by individually measuring the cartons entering the system and then cutting them open at the two short top edges and in the middle of the top of the carton using triple adhesive tape. Now all the flaps are sucked in, cut off completely and land on the outfeed conveyor. In the next step, robot arms then pick the goods out of the completely open cartons. Two of the new ROC-4flaps opening systems were integrated into the American customer's newly built warehouse. The ALS technology ensures that, for example, delivered textiles are not cut even if they have been stuffed tightly into the carton and are pressing against the inner walls. This system is currently suitable for parcel sizes from 200 x 200 x 200 mm up to 800 x 600 x 500 mm.

Protection for employees and goods

According to the company, the systems developed by ALS perform five times better than manpower, but only cost as much per year as a single worker. ALS calculates that it is therefore possible to save more than three million euros within 15 years in a single-shift operation. One customer describes the parcel opener he uses as "the best functioning machine in our logistics", and the logistics planner responsible for an e-commerce customer speaks of "exclusively positive effects": The new process sequence saves employee capacity, prevents cutting injuries and, last but not least, protects the box contents. ALS launched the first automatic parcel opener on the European market in 2013. The first innovations were aimed at making work in the warehouse easier and minimizing errors when opening. The first prototypes were an immediate success and are still running to the complete satisfaction of customers today. However, with further developments in sensor technology, robotics and cutting technology, automation has become even more precise and accessible.

Customized applications

"It's always a pleasure to develop customer-specific solutions," says Paul Kammerscheid, founder and managing partner of ALS Automatic Logistic Solutions. His new customer in the USA is by no means only dealing with returns shipments, but rather with new goods in classic incoming goods, which are unpacked in the warehouse and then sent on to customers in small quantities. The annoying sorting out of damaged goods is no longer an issue thanks to ROC 4flaps.

Years ago, Paul Kammerscheid secured funding from business angels for his vision of optimizing logistics processes with efficient machines, which was the starting signal for rapid expansion. In addition to the capital, Kammerscheid also benefited from his contacts in the logistics industry. His customer base now includes cross-sector market giants such as Bayer, Bosch, Decathlon, H&M and the OTTO Group. The future is not far off Parcel opening systems already work very precisely, but further developments are to be expected. Future machines will not only be able to open parcels, they will also be able to identify and sort their contents. They will be able to scan damaged incoming goods before they are opened and even document such processes independently. Logically, sustainability will also play an increasingly important role. This is because future opening systems will be able to separate materials in ever greater detail and sort out recyclable materials. Further milestones for more environmentally friendly logistics processes are therefore on the way. Paul Kammerscheid is currently working on the next step: "In addition to carton opening, we also have a lot of plans for 'bag opening'".