Since December 2025, ORAFOL’s shipping department has been operating with a new fully automated pallet packaging system combined with autonomous mobile robots. The project shows how technical innovation, well-designed processes and cross-functional collaboration can create real value in day-to-day operations.
Rethinking Shipping
THE ORAFOL PROJECT TEAM, FROM LEFT TO RIGHT: CHRISTIAN MÜLLER, PROCESS ENGINEER; MARCO WEISS, HEAD OF SHIPPING; AND NANDO KERSTEN, TEAM LEADER FWL AND LOGISTICS COORDINATOR.
From concept to 24/7 operation
The project began around one and a half years earlier as part of the “Shipping Optimization” initiative. Together with an external consultancy, the entire shipping team explored how processes could be further developed both technically and organizationally. It quickly became clear that, rather than adapting existing solutions, a new automated packaging system should be developed from the ground up – tailored specifically to the requirements of ORAFOL’s shipping operations.
Following a structured supplier selection process, the decision was made in favor of Signode, a globally leading provider of packaging and load containment solutions. This decision was based on a comprehensive preliminary study, including extensive stability testing in Denmark. The result was a new stretch-wrapping process that significantly reduces packaging material while maintaining the same pallet stability. In December 2024, the decision was made to invest in the new pallet packaging system and to further expand the use of autonomous transport technology.
MOBILE ROBOTS COLLECT FINISHED PALLETS FROM THE PACKING STATIONS AND TRANSPORT THEM TO THE CONVEYOR SYSTEM OF THE NEW PACKAGING LINE.
Why invest in a new packaging system?
“The new system is a key part of the ongoing development of our shipping operations,” explains Marco Weiß, Head of Shipping at ORAFOL. “Requirements regarding packaging stability, legal compliance, efficiency and cost-effectiveness have changed significantly.”
One major advantage of the new system is that it reduces packaging material consumption by up to 60 percent while maintaining the same pallet stability. At the same time, automation noticeably reduces manual workload and creates additional capacity for future growth.
THE PROJECT TEAM REPLACING THE STRETCH FILM: THE NEW SYSTEM USES UP TO 60 PERCENT LESS PACKAGING MATERIAL.
Technical challenges – solved pragmatically
The conditions in shipping were demanding. “Available space is limited, which is why the system was implemented in a compact U-shaped layout,” says Christian Müller, Process Engineer and member of the project team. At the same time, the solution needed to be as versatile as possible – capable of handling everything from standard pallet formats to high-cube pallets for overseas containers and oversized air freight pallets. Today, around 97 percent of all pallet formats can be packaged automatically.
Another challenge was ensuring the safe interaction between the new packaging system and the autonomous mobile robots. This was solved through a clearly defined electronic request and approval process between the robot control system and the packaging system. The result is a stable, transparent and reliable material flow – even in 24/7 operation.
Beyond the technology itself, collaboration was a decisive factor in the project’s success. Over the course of several months, teams from shipping, IT, engineering and sales worked closely together, contributing different perspectives and jointly developing solutions to new challenges.
THE MOBILE ROBOTS TAKE OVER TRANSPORT TASKS, WHILE THE NEW SYSTEM HANDLES THE PACKAGING PROCESS – REDUCING MANUAL EFFORT AND SAVING VALUABLE TIME.
Mobile robots as a logical next step
The idea of using autonomous mobile robots emerged directly from the process analysis in Hall 3. “We realized that transporting pallets to the packaging system is a repetitive, standardized task – ideal for automation,” says Nando Kersten, Teamleader FWL and Logistics Coordinator as well as project lead.
Two ERC 217a mobile robots from Jungheinrich are now in use. They collect finished pallets from the packing stations and transfer them to the conveyor system feeding the packaging line. Transport requests are triggered with a simple mouse click. The vehicles are designed to handle not only Euro pallets, but also special pallet formats. Safety was a key priority throughout the implementation: in addition to obstacle detection, extra sensors ensure reliable protection for personnel at all times.
THE NEW TECHNOLOGY GIVES EMPLOYEES THE OPPORTUNITY TO DEVELOP THEIR SKILLS FURTHER BY WORKING WITH STATE-OF-THE-ART LOGISTICS SYSTEMS.
Tangible benefits in everyday operations
The benefits of the new solution are clearly visible in daily operations. Top sheets, edge protectors, cover sheets and strapping bands are applied automatically, while the mobile robots handle pallet transport. This reduces manual work, increases efficiency and improves process reliability. At the same time, the new technology opens up new opportunities for employees to develop their skills in modern logistics operations.
By combining a fully automated packaging system with autonomous mobile robots, ORAFOL has taken its shipping processes to a new technological level. The project shows how well-designed automation not only saves costs and materials, but above all relieves employees and strengthens future readiness. It is a strong example of how innovation can make a concrete difference in everyday industrial operations.
