A new era for packages

The package opener is making its way into retail stores and small businesses

Grünwald, September 2019. Retail stores and online shops are set to undergo a revolution. ALS Automatic Logistic Solutions GmbH has developed the first “XS” version of its automatic package opener, designed for small to medium-sized businesses and retail store solutions. The semi-automatic JUPI is cost-effective even with a moderate package volume of 300–1,500 per day.

ALS Automatic Logistic Solutions GmbH, based in Grünwald near Munich, is known for its automated package-opening solutions in intralogistics—especially since there are no comparable competitors anywhere in Europe. Now, in response to high demand, the machinery manufacturer has launched its first semi-automatic machine designed for the package volumes typical of small and medium-sized enterprises (SMEs).

“It’s time for a new era,” says Paul Kammerscheid, CEO of ALS. “In countless companies, several employees still spend hours every day opening heavy packages manually with box cutters. We’re finally solving this very problem: With the new JUPI system, employees can focus on more important tasks.”

“Only one employee is needed to operate the JUPI. After goods are delivered, the employee can use the semi-automatic JUPI to open the packages quickly, efficiently, and without causing cuts to employees, damaging the goods, or lifting heavy loads, and then move on to other tasks.”

The key feature: Using three electrically powered cutting axes, JUPI opens the boxes on three of the four sides. This “hinge cut” is particularly popular because the lid cannot get lost, ensuring that items such as return labels remain attached to the product until it is finally unpacked. This system offers entirely new possibilities—across all industries—especially for the ever-growing e-commerce sector and retail stores.

All of ALS’s existing systems operate both efficiently and fully automatically, serving industry giants in automated order picking, returns processing, shipping optimization, and goods receiving. These automated systems can open up to 1,200 boxes per hour. Unlike manual knives operated by employees, ALS’s package openers no longer cut into the goods. The resulting efficiency gains, reduced waste, and elimination of the risk of injury to employees are key factors in the success of the package openers.

The production-ready JUPI will be unveiled to the public for the first time at the FachPack trade show in Nuremberg from September 24 to 26, 2019.

 

 

 

FachPack 2018: BOS package opener with even smarter cutting technology

The BOS package opener will control the cutting process in the future

Munich, August 10, 2018. ALS Automatic Logistic Solutions GmbH of Munich, a leading European manufacturer of automatic package-opening systems, will present the full range of its product portfolio—which now includes eleven different cutting machines—at this year’s FachPack in Nuremberg (September 25–27, 2018). ALS will also impress trade visitors with an intelligent modification of its “flagship” product, the Box-Opening System (BOS). Thanks to upstream image processing, this system will in the future be able to determine whether a container (such as a mesh box) needs to be cut open or not. BOS thus independently decides during the ongoing processing whether to cut open a carton or, if necessary, routes it unprocessed past the cutting heads as a container unit (also possible on a tray). The customer can therefore feed all containers through the BOS system unsorted and in a chaotic manner via the conveyor system.

Thanks to their wide range of capabilities, ALS cutting machines can handle almost any application in receiving, returns processing, order picking, and shipping optimization. Capacity ranges—depending on the system—from 400 to 1,200 cartons per hour. Depending on the package size, the BOS cutting system can open up to 600 shipments per hour or 14,000 units per day. The standard system is capable of opening package sizes ranging from 160 x 140 x 110 mm to 600 x 600 x 400 mm (other sizes available) five times faster than manual handling, without prior sorting.

BOS automatically detects the dimensions of each package via integrated sensors and adjusts the cut accordingly. A sensor monitors the workflow and detects when the cutting process is complete, allowing the next box to be fed in via the standardized roller conveyor. This makes it easy to integrate the system into existing conveyor lines. Due to the advantages described in the process of opening cartons and packages, the BOS system pays for itself on average within 12 months compared to manual opening—and the associated allocation of personnel resources.

Trade visitors can find ALS Automatic Logistic Solutions at FachPack 2018 in Hall 4A at Booth 228.

 

 

— 2016 Handling Award for WIM —

The WIM Package Opener has been awarded this year's Handling Award.

The WIM package opener from European market leader ALS has been awarded the “Handling Award”

Munich/Stuttgart, October 2016 – At MOTEK 2016 in Stuttgart, the WIM automatic package opener was honored with the Handling Award.

Opening boxes and packages without damaging the contents is becoming an increasingly significant time and cost factor in logistics. The solution to this pressing problem comes from the automatic package openers developed by the European market leader, ALS Automatic Logistic Solutions GmbH, based in Munich. Their WIM package opener has now been honored with the Handling Award. WIM is a fully automatic package opener that perforates or cuts a window in the front of a carton. This makes picking easier during manual order fulfillment, significantly speeds up the process, and substantially reduces costs.

If the window is initially to be perforated only, it can be removed later—without tools. This allows large quantities of cartons to be prepared mechanically—without damage—for tasks such as order picking.
The WIM package opener can be installed in the receiving area, behind the automated small-parts warehouse (AKL), or directly in front of the flow rack.

The cartons enter the WIM system chaotically and sporadically from a roller conveyor. The carton is then clamped and measured (LxWxH). A vacuum suction cup is then positioned centrally on the front side. The carton tilts backward to reduce any pressure the contents may exert on the inner wall of the carton. The vacuum suction cup attaches to the front face to further relieve any remaining pressure. The rotary cutter begins cutting or perforating to the predefined cutting depth and window size.

After cutting, the window is removed by the vacuum suction cup—and later removed without tools during perforation. The cardboard sheet tilts back to a horizontal position. The cardboard sheet exits the system. Cardboard sheets unsuitable for the system can be ejected beforehand by an upstream defect detection system.

The system is capable of opening packages ranging in size from 200 x 200 x 200 mm to 600 x 600 x 400 mm five times faster than manual handling, without any prior sorting. This enormous throughput significantly reduces picking costs.

Depending on the package size, WIM can open up to 500 boxes per hour or 12,000 units per day. Since the machine requires no breaks and does not slow down due to fatigue, it achieves an overall time efficiency ratio of 5:1 compared to manual labor. The WIM automatic package opener is equipped with Kuka industrial robots and a Siemens SPS 7 controller.

Compared to manual opening—and the allocation of the necessary personnel—WIM pays for itself in about ten months. Due to the system’s high cost-effectiveness, its development is supported by public funding.

 

— PRESS RELEASE: ZAR Automatic Package Opener —

The ZAR automatic box opener can open up to 900 boxes per hour using a side cut!

Munich, November 5, 2015 – Shortly after the successful unveiling of the TOM automatic package opener at FachPack 2015 in Nuremberg, its sister model, the ZAR, is now also available.

ZAR rounds out the line of standardized package openers from ALS GmbH, a Europe-wide specialist in automated package openers for incoming goods and returns, order picking, and shipping optimization.

Opening boxes and packages without damaging the contents is becoming an increasingly significant time and cost factor in logistics. The booming online retail sector, in particular, is facing an increasing number of boxes. Following the recent completion of TOM’s development, another automatic package opener is now available, featuring additional methods and processes. While TOM opens packages by cutting the tape on the top of the box, ZAR can cut packages open from the side.
ZAR can open cartons as low as 50 mm in height with a single-sided or double-sided cut in a single operation.

This new, automatic ZAR (timing belt drive) package opener is suitable for side cuts and is primarily designed for flat cardboard boxes, such as samples, maxi-letters made of cardboard, documents, etc.

Optionally, the carton can be rotated using a subsequent 90° turner so that it can be cut along two additional side edges at the next station, thereby separating the carton into two parts.
The ZAR package opener system can quickly and efficiently open packages measuring 160 x 140 x 50 mm (LxWxH) or larger on the side using a fixed blade without damaging the products inside. ZAR can be used for cartons up to a maximum size of 800 x 600 x 500 mm and can also be configured in various ways to meet different practical application requirements. ZAR can efficiently and automatically open up to 900 packages per hour.

ZAR is available in three versions:

ZAR – M
The M model is designed for cartons of uniform width and height. The longitudinal cut on the side is always made at the same height.
ZAR – H
With the H model, the width of the cartons is the same, but the height can vary; the longitudinal cut on the side can be made at different heights, depending on the height of the carton.
ZAR – HW
With the HW model, the cartons can vary freely within the minimum and maximum values. The carton size is measured individually for each incoming carton, the vertical straps are adjusted to the appropriate width, and the cutter is moved to the desired height.

The ZAR system is about three times as efficient as manual labor and also prevents injuries that cannot be ruled out when opening manually.

The cost savings achieved by using a machine instead of manual labor amount to approximately 80%.

ZAR Package Opener

The new ZAR package opener from ALS, Europe's leading specialist in automatic package openers, triples the capacity of the goods and returns receiving area.

ALS’s innovative ZAR package opener can automatically cut open cartons ranging in size from 160 x 140 x 50 mm to 800 x 600 x 500 mm without the need for pre-sorting. The system opens packages and cartons along the long side three times faster than manual methods, thereby reducing costs by approximately 80%.

The ZAR package opener is designed to cut open cardboard boxes along the long side—either on one side or both sides. It is primarily used for flat cardboard boxes to remove items such as samples, eyeglasses, documents, and spare parts.

 

 

 

 

 

— TOM Tape-Only Method —

Open over 7,000 boxes per shift efficiently and automatically using tape-cutting technology! Featured at FachPack.

 FachPack Premiere: The TOM package opener from ALS opens up to 900 boxes per hour by cutting the tape.

 Munich/Stuttgart, September 2015 – The TOM automatic package opener will be unveiled at FachPack 2015 in Nuremberg. With this addition of another standardized package opener, ALS GmbH is expanding its product range and establishing itself as the Europe-wide specialist for automated package openers in goods and returns receiving.

Opening boxes and packages without damaging the contents is becoming an increasingly significant time and cost factor in logistics. The booming online retail sector, in particular, is facing a growing volume of boxes. To open only the longitudinal tape on the box, ALS Automatic Logistic Solutions GmbH, Munich, has developed another—globally unique—solution to this problem in addition to its successful automatic package openers BOS, WIM, and ROC: TOM—a fully automatic package opener that opens over 7,000 packages per shift by cutting the tape on the top of the box.

This new automatic package opener, TOM (Tape-Only Method), is specifically designed for cardboard boxes that are sealed lengthwise only in the center with adhesive tape and are intended to be cut open only along the length. The system is therefore suitable for relatively uniform cardboard boxes—such as those from a single production run—that are intended to be reused.

 

Many manufacturers, wholesalers, and shipping companies ship goods in standardized boxes sealed with packing tape. When opening these boxes, the tape is often simply cut through so that the boxes can be reused. This applies both to repackaging goods and to the subsequent reuse of the boxes in order picking.

The TOM package opener system can quickly and efficiently open packages measuring 160 x 140 x 100 mm (LxWxH) or larger using a multi-blade mechanism on the top side, without damaging the contents. TOM can be used for cartons up to a maximum size of 600 x 600 x 500 mm and can also be configured in three different ways to accommodate various practical applications.

If the returns receiving area receives boxes that are all identical, the TOM system can be configured with preset height and width settings, and the boxes can be fed through the multi-blade cutter via a conveyor belt. The blades then ensure that even diagonally applied packing tape is cut cleanly, so that the package is securely opened and the contents can be easily removed.

If the goods arrive in boxes of different sizes, TOM can alternatively be configured with variable height detection, allowing it to open packages of varying heights.

If the incoming packages are even less standardized, TOM can not only automatically calibrate and position the blades to the correct height, but also automatically detect the width of the boxes and secure them in place.

In all these cases, up to 900 boxes per hour can be opened safely and reliably at the incoming goods or returns area.

Since the machine does not require breaks and does not slow down due to fatigue, it achieves an overall time efficiency 2.5 times greater than manual labor and also prevents injuries that cannot be ruled out when opening manually.

The cost savings achieved by using machines instead of manual labor amount to approximately 80%.

 

 

 

— ROC Robot Cell —

Automated depalletizing, unpacking, and processing of cartons

Depalletizing robots and package openers now work in tandem and can be installed precisely according to customer specifications, even in the tightest of spaces.

In addition to the efficient BOS and WIM package-opening systems, ALS Automatic Logistic Solutions GmbH now also offers custom-designed combinations of package openers and additional industrial robots that work “hand in hand” to further automate goods receiving and production. Such a ROC robot cell (one or more robots) is used wherever reliable complete solutions for unpacking and further processing goods are required.

Faster processing of cartons to be emptied through depalletizing, automatic opening, and subsequent automatic processing or transfer to downstream units leads to a significant increase in efficiency. In addition, the physical strain on employees and the risk of injury are further reduced considerably.

Receiving deliveries, depalletizing boxes, opening boxes, and then removing the goods and sending them to production or the warehouse—these are monotonous, repetitive tasks that are ideally suited for automation. ALS Automatic Logistic Solutions GmbH, which has automated the opening of boxes and packages without damaging the goods using globally unique and patented package openers, now also supplies complete, customized systems that automate the entire goods receiving process using adapted industrial robots.

Depending on the customer's requirements, such a system may consist of a depalletizer, a package opener, and conveyor systems, as well as downstream solutions for further processing of the goods—such as unloading or removing the goods, or stripping off plastic bags—all the way through to the removal of used cardboard boxes.

Thanks to the use of modern industrial robots, such a ROC (robot cell) system can be integrated into existing facilities in even the most confined spaces and customized to suit specific applications.

A ROC robotic cell either includes specialized cutting blades for specific applications or is connected to the fully automatic package openers BOS or WIM from ALS GmbH, enabling it to process even disorganized incoming shipments quickly and efficiently.

The BOS (Box Opening System) automatic package opener uses cutting technology to open packages and cartons—without pre-sorting—at a rate of up to 600 units per hour or 14,000 units per day. Several blade options are available, allowing for eight different cut types and opening the cartons in a manner optimized for specific subsequent processing.

With its cutting technique—which involves cutting a window into one end of the box—the automated package opener WIM (Windows Method) offers an optimal solution for order picking and packaging.

With ROC, a flexible—robot-assisted—system is now available as a complementary solution that can be used in a practical manner for any application, such as in goods receiving or production, and can be flexibly adapted to on-site requirements.

Visuals

 

Motif 1

ROC is a custom-designed product consisting of a depalletizer, package opener, and conveyor systems, as well as solutions such as unloading, product retrieval, and film bag removal—all the way through to cardboard disposal.

 

 

 

 

Motif 2:

ROC as a custom-built robotic cell for depalletizing and further processing (steps 1 and 3), BOS for opening the cartons (step 2).

 

 

 

 

 

 

— BOS Box Opening System —

Automatically open 600 boxes per hour—even when incoming shipments are disorganized

The BOS system from ALS Automatic Logistic Solutions GmbH can open a cardboard box in just 6 seconds—without damaging the contents, of course. This is the most advanced and highly automated technology for goods receiving available worldwide.

With six different cutting modes and eight cutting depths offered by the BOS system, logistics managers can now increase efficiency in goods receiving by up to 70%. At the same time, the inherent risk of injury to employees associated with manual opening is reduced to zero.

Thanks to the specialized technology, which has been developed and tested by experts over the past few years, any damage to the goods is completely ruled out. Whether plastic wrap containing goods or additional boxes—such as retail boxes—are located behind the walls of the outer carton to be opened, the BOS system opens the outer carton in question and not the goods themselves.

Prospective customers can learn more at any time about how these systems can be used in goods receiving, returns processing, order picking, and goods shipping. ALS’s automatic package openers are suitable for use in industry, fulfillment, shipping, and wholesale.

 

— WIM Windows Method —

Open the box efficiently and without damage!

The WIM package opener opens boxes at the front

In logistics, quickly opening boxes and packages without damaging the contents is often a time-consuming and costly process. The booming online retail sector, in particular, is facing an increasing volume of boxes. Against this backdrop, ALS Automatic Logistic Solutions GmbH, Munich, has launched a unique solution: a fully automatic package opener that cuts a window-shaped opening in the front of cartons. This facilitates easier picking during manual order fulfillment.

ALS's innovative WIM (Window Method) package opener can automatically cut or perforate a window in the front of a cardboard box, in case the window is to be removed later—without the need for tools.

This means that large quantities of boxes can now be prepared mechanically without damage, for example, for order picking.

The WIM package opener can be installed in the receiving area, behind the automated small-parts warehouse, or directly in front of the flow rack.

The cartons enter the WIM system chaotically and sporadically from a roller conveyor. The carton is clamped and measured (LxWxH). A vacuum suction cup is positioned centrally on the front side. The carton tilts backward to reduce any pressure the contents may exert on the inner wall of the carton. The vacuum suction cup draws the front face toward it to further relieve any remaining pressure. The rotary cutter begins cutting or perforating to the predefined cutting depth and window size.

After cutting, the window is removed by the vacuum suction cup—and later removed without tools during perforation. The cardboard tilts back to a horizontal position. The cardboard exits the system.

Cartons that are unsuitable for the system can be diverted beforehand by an upstream defect detection system.

The system is capable of opening packages ranging in size from 200 x 200 x 200 mm to 600 x 600 x 400 mm five times faster than manual handling, without any prior sorting.

Depending on the package size, WIM can open up to 500 boxes per hour or 12,000 units per day. Since the machine requires no breaks and does not slow down due to fatigue, it achieves an overall time efficiency ratio of 5:1 compared to manual labor. This means the system pays for itself in about ten months compared to manual opening—and the associated allocation of personnel resources. Due to the system’s high cost-effectiveness, its development is supported by public funding.

 

— BOS Box Opening System —

 

New package opener from ALS increases capacity fivefold

Munich, September 2013. In logistics, opening packages quickly and securely often involves significant time and cost. For example, the booming online retail sector is facing an increasing number of returns. As a recent study by the market research institute Dialego shows, the return rate for outerwear in 2011 was nearly 75 percent! Even at e-commerce giant Zalando, the rate is well over 50 percent. Against this backdrop, ALS Automatic Logistic Solutions GmbH, Munich, together with developer Bernhard Hörl, has launched a system solution that is unique in Europe: a fully automatic package opener that performs the process of opening a wide variety of packaging formats five times faster than by hand.

ALS’s innovative box opening system offers four different cutting options. With the full cut, a removable lid is created, whereas with the hinge cut, one side of the package remains closed, allowing the packaging to be easily opened. If the packages are to be transported closed within the facility, BOS offers the perforation cut. In this case, a small cardboard tab remains at each corner. This protects the goods until the lid is completely removed by hand. Additionally, the BOS can open longitudinally glued folding cartons along the entire length of the package using a tape cut. The method by which the system cuts open the package can be individually selected via a control display. The cutting depth can also be continuously adjusted between 4 and 11 millimeters to prevent damage to the goods.

The system is capable of opening packages ranging in size from 160 x 140 x 120 mm to 600 x 600 x 400 mm—without prior sorting—five times faster than manual handling. Using integrated sensors, the BOS automatically detects the dimensions of each package and positions the cut accordingly. A laser tracks the workflow and detects when the cutting process is complete, allowing the next carton to be fed in via the standardized roller conveyor. This enables the system to be easily integrated into existing conveyor lines.

Depending on the package size, the BOS can open up to 600 shipments per hour or 14,000 units per day. Since the machine requires no breaks and does not slow down due to fatigue, it achieves an overall time efficiency ratio of 5:1 compared to manual labor. As a result, the system pays for itself—compared to manual opening and the associated allocation of personnel resources—in less than ten months on average. Due to the system’s high cost-effectiveness, its development was funded by the Central Innovation Program for SMEs (ZIM) of the Federal Ministry of Economics and Technology.