Thegoods receiving area is the bottleneck of any efficient intralogistics operation. When packages and boxes pile up here, the entire downstream process—from putaway to order picking to shipping—is delayed. In an era of chronic labor shortages and steadily rising package volumes, manual labor using box cutters is simply no longer enough to remain competitive.
In this comprehensive guide, you’ll learn how to sustainably optimize your incoming goods process, drastically reduce labor costs, and significantly improve employee safety at the same time. The key to achieving this lies in automation using state-of-the-art automatic package openers from ALS Box Opening.
The 3 biggest problems with manual goods receiving
1. Inefficiency & high labor costs
Opening boxes manually is an extremely time-consuming and error-prone process. Under ideal conditions, a skilled employee can handle a maximum of 100 to 150 packages per hour. If your volume increases due to seasonal fluctuations or business growth, labor costs will rise proportionally.
2. Increased risk of injury & absenteeism
The constant use of sharp knives in a high-volume work environment regularly leads to cuts in the logistics sector. Every day an employee is absent not only costs your company money directly but also places an additional burden on the remaining staff due to the extra workload.
3. Significant product damage (cut damage / shrinkage)
An employee who opens hundreds of packages a day is bound to make mistakes. One cut too deep, and the goods inside are ruined. A package opener that prevents damage to goods can save companies five- to six-figure losses each year.
The solution: Automation using a package opener machine
The most effective and cost-efficient way to optimize incoming goods processing is consistent, automated package opening. With a package opener from ALS Box Opening GmbH, you can eliminate all problems at once:
- Extreme throughput of up to 1,200 cartons per hour: A fully automated system like our ROC Robot Cell is the ideal carton opener for incoming goods and returns.
- Zero damage to goods guaranteed: The patented cutting technology (e.g., in the BOS package opener) operates with a precisely defined cutting depth.
- Maximum workplace safety: Enclosed systems—no exposed blades in the work area.
- Chaotic feeding without pre-sorting: Our systems dynamically detect different box sizes in milliseconds.
ROI Calculation: Payback Period for Package Openers in E-Commerce
Many logistics and procurement managers are looking for information on the price and ROI of package-opening machines. A company that processes, for example, 4,000 return packages per day would need approximately 4 to 5 full-time employees to open them manually. A return package-opening system like the ZAR Package and Carton Opener can handle this work effortlessly on its own.
Across all industries, the average payback period for an ALS system among our customers is just 12 to 24 months.
Practical tip: The right machine cut
- Full-cut: The lid is cut off all the way around and discarded immediately. Perfect for quick repackaging.
- Partial cut / hinge cut: The lid is cut open on three sides. Ideal for cardboard box openers and returns.
- Window cutout: Large opening at the top. Specialist: WIM package opener.
- Tab cutting: Precise cutting of the top tabs. The JILL package opener handles this with ease.
- Cutting tape: Keep the box intact – TOM Package Opener.
Short on space? The semi-automatic package opener
Not every receiving area has the space for a fully automated system. That’s exactly why we offer semi-automated solutions. A semi-automated package opener or the PUSH package opener —our inline specialist—delivers state-of-the-art ALS cutting technology in a compact design.
Conclusion: Make your goods receiving process future-proof
If you’re serious about optimizing your incoming goods process and want to scale it up, an automatic box opener is a must-have. Invest in an ALS package opener for the highest quality.
Ready to take the next step toward automation?
Contact us for a cost analysis comparing package openers to manual labor.
