Ironmongery Direct needed a new void fill system to keep up with increasing order volumes as their warehouse layout changed. They were using airbags and paper previously but it led to bottlenecks. Ranpak designed a custom side-loading FillPak system integrated over the conveyor to fill boxes directly at the packing point for high throughput. The new system allows them to cope with daily peaks of 500 boxes filled.

1. The Paper Packaging Experts™
Customer challenges
Prior to using Ranpak, both airbags and an alternative paper
system were being used. There were no specific issues as
such with the use of these products in the early days, but as the
warehouse layout changed due to company growth in orders,
the solutions that were being used, were leading to bottlenecks.
Careful deliberation of the future expactations of the warehouse
setup and voidfill requirements took place. It was clear that with
an end of line approach being adopted that the Ranpak FillPak
standard would best meet the needs. Working with both the
customer and the distributor, a design was proposed that took all
aspects into consideration. Several designs were considered, but
the integration offered by the Fillpak system served the needs
best. The system needed to be directly at the point of packing, and
throughput has to be maintained especially at peak times, were the
main needs. Also ease of use and convenience were requirements.
Hardware:
Ironmongery Direct
In 2013 Ironmongery Direct was acquired by Manutan,
and still operates in its founding town of Basildon, and are
the UK’s largest supplier of architectural ironmongery to
builders, joiners and shop fitters. Increasingly, the online
business has grown and developed and is now a major
part of the business.
In cooperation with our Distributor
Business results
“The system now in place works well and can
cope with the daily throughput peaks, because
of the speed FillPak works at”
Ranpak BV
T +31 88 255 11 11
E eu.info@ranpak.com
www.ranpakeurope.com
Our Solutions
The conveyoring already in place did not allow for a standard FillPak machine to fit, so a bespoke integration was
designed, constructed and installed by Ranpak to meet the needs of Ironmongery Direct.
The system is a side loading FillPak integration constructed on a frame that is fixed over the conveyor. The paper cart
is located at the side of the frame, which allows easy access for the team to load the paper. This means ease of use of
a void fill system for the team, because the system is located, as needed, over the area where the boxes stop for filling.
Allowing a throughput of 500 boxes per day.
Impression packaging at Ironmongery
Hardware that needs optimal protection
Ironmongery Direct was formed in Basildon Essex in 1969 as a traditional
Ironmongers shop and now employs over 100 people.
Tom Ramshaw, Head of Operations
With such rapid expansion, solutions needed to be found
for a packing operation that meets demands now and also
into the future. Solutions had to meet the rapid expansion
of the company, and after several warehouse layout
operational workings, it was decided that an end of line
solution would be needed.