As orders surged, the retailer’s nimble operation began to strain under pressure. Managing over 120 different box sizes and manually consolidating shipments proved slow and labor-intensive. The sprawling facility, once a mark of growth, was becoming a bottleneck. The company needed to find a way to:
Reflecting on the journey, the retailer’s CEO shared, “We pretty much designed all of our workflow processes around the assumption that these automation pieces exist. The result has been a higher throughput, a lower cost per package, and a higher quality output.”
Siggins led the charge in project management and system integration, working closely with Packsize, OPEX, Hytrol, and the retailer’s team. As Matt Gibson, Project Manager at Siggins, described, “My role is to bring everyone together—multiple vendors, installers, and the customer—to keep everyone talking and on the same page.”
As Kip Peters, Principal Solutions Partner at Siggins, explained, “There’s a lot of technologies in warehouse automation. Individually, they’re good—but when you put them all together, they become great. That’s really what Siggins does.”
The integrated solution delivered transformative results. Almost overnight, staff noticed a difference. Orders moved faster, and the team spent less time searching for the right box or sorting shipments by hand. Key improvements included:
The retailer’s CEO summed up the impact: “We’ve stayed in the same facility longer because, without these processes, we’d have outgrown this space. Oddly enough, with all the complexities of automation, we’ve actually decreased the training time and [improved] consistency of work for our staff.”
Packsize
Ryan Johnson, Regional Sales Manager:
“SMART Packaging for a Healthy Planet really stems from our ability to right-size every order, driving out waste in packaging. When you right-size, you fit more boxes on every truck, which translates to less trucks on the road and less emissions.”
Siggins
Kip Peters, Principal Solutions Partner:
“We like to work with privately owned companies, where we can sit face-to-face with ownership and leadership that’s highly engaged. We started with a conveyor project, gained trust, and grew together as their business evolved.”
Matt Gibson, Project Manager:
“When a problem comes up and you can solve something for the customer, there’s no better feeling.”
OPEX
Charlie Bedaux, Partner Coordinator:
“With the Sure Sort X, we satisfied a much larger product range for this company. It’s mostly the labor savings, but also minimizing mis-shipments and consolidating sortation into one system—plus the space savings.”
For this top e-commerce toy retailer, working with Siggins and Packsize has delivered a scalable, efficient, and future-ready fulfillment operation. Automation and right-sized packaging have helped the company grow, delight customers, and operate sustainably—while always staying prepared for whatever comes next.
Interested in learning more about integrated automation and right-sized packaging for your business? Contact Packsize to schedule an evaluation today.
