Packsize Machines: Revolutionizing Packaging with Innovation


In today’s industries, Packsize machines are revolutionizing automated packaging by creating right-sized boxes on demand. This innovation not only increases efficiency but also reduces costs and optimizes warehouse space. If you’re short on time, here are the key benefits of Packsize machines:

  • Automated Packaging: Eliminates manual packing challenges.
  • Right-Sized Boxes: Customizes box sizes to fit products perfectly.
  • Cost Savings: Reduces material and shipping costs.
  • Sustainability: Uses eco-friendly materials, minimizing waste.
  • Speed: Achieves high throughput, essential for high-volume centers.

Packsize machines are transforming packaging operations across various industries by combining speed, precision, and sustainability. They streamline workflows, optimizing the entire packaging process to meet the needs of modern businesses.

Key benefits of Packsize machines - packsize machine infographic pillar-5-steps

What is a Packsize Machine?

A Packsize machine is an automated packaging system that creates right-sized boxes on demand. Designed to streamline the packaging process, these machines are revolutionizing the way businesses handle their shipping needs.

Automated Packaging

Packsize machines automate the entire packaging process, eliminating the need for manual packing. This means you no longer have to worry about hiring and training additional warehouse employees, especially during peak seasons. For instance, the X7® box making machine can produce a packed and ready-to-ship product every 3.5 seconds. This level of automation significantly increases productivity and reduces labor costs.

Right-Sized Boxes

One of the standout features of Packsize machines is their ability to create right-sized boxes. These boxes are custom-made to fit the exact dimensions of the product being shipped. This not only reduces the amount of corrugated material used but also minimizes the need for void fill, which is often non-recyclable. According to Rod Gallaway, CEO of Packsize International, “On-demand carton creation results in cartons that form tightly around the product or products being shipped,” enhancing the customer experience by reducing waste and improving package integrity.

On-Demand Packaging

Packsize machines use advanced technology to produce boxes on demand. This means that each box is made only when needed, based on real-time data from warehouse management systems. The PackNet® Cloud software integrates seamlessly with existing systems to control the packaging process from start to finish. This ensures that every box is the right size, reducing material costs and shipping expenses.

Top Packsize Machines Transforming the Industry

X4®: Compact and Efficient

The X4® is a game-changer in packaging. Its small footprint of just 134.5 square feet makes it perfect for warehouses with limited space. Despite its compact size, the X4 packs a punch with its 4-in-1 function. It can cut, crease, glue, and label boxes, all in one machine. This means you don’t need multiple machines or constant operator attention.

By automating these tasks, the X4 reduces labor needs, allowing businesses to reallocate workers to more critical areas. The machine produces right-sized boxes on demand, which can reduce the average size of your boxes by up to 40%. This not only saves material but also lowers shipping costs by reducing Dimensional Weight (DIM) charges.

X5®: High-Volume and Versatile

For businesses with high-volume demand, the X5® is the ideal solution. This machine can produce up to 600 ready-to-pack boxes per hour. It is perfect for e-commerce and manufacturing businesses that need to keep up with a fast-paced environment.

The X5 is versatile and can handle RSC style boxes, which are commonly used in various industries. It incorporates lean manufacturing principles, streamlining your packaging processes and improving efficiency. The X5 also reduces labor by integrating eight automation features, making it a reliable and cost-effective choice for high-volume operations.

X7®: Speed and Reliability

If speed is your priority, then the X7® is the machine for you. This machine can produce a box in just 3.5 seconds, making it one of the fastest on the market. With the ability to handle both single-item and multi-item orders, the X7 is incredibly versatile.

The X7 incorporates a top-down glue application, which ensures a secure and clean seal for every box. It also reduces the amount of corrugated cutting to two positions, minimizing dust and scrap. This machine can produce up to 1,020 boxes per hour, making it perfect for businesses that need to keep up with high demand, whether during peak season or in the off season.

How Packsize Machines Work

Packsize machines are designed to create custom, right-sized boxes on demand. Here’s a breakdown of how they work:

z-Fold Corrugated

Packsize uses a special material called z-Fold corrugated. This material is fed through the back of the machine. The z-Fold is versatile and can be made into almost any FEFCO-style box.

Cutting, Creasing, and Scoring

Once the z-Fold is in the machine, it gets cut, creased, and scored to match the exact specifications needed for the box. This process ensures that each box is perfectly sized for the product it will contain.

Dimensional Data

The dimensions for each box can be input in several ways. You can enter them manually, scan them, or integrate them through an existing Warehouse Management System (WMS). This flexibility ensures that the machine can quickly adapt to different packaging needs.

Integration with Warehouse Management Systems

Packsize machines can seamlessly integrate with Warehouse Management Systems. This means that as soon as an order is processed, the machine receives the dimensional data and starts creating the right-sized box. This integration streamlines the entire packaging process, making it more efficient and less prone to errors.

Automated Workflow

Once the box is cut, creased, and scored, it is ready for assembly. The machine can handle this automatically, reducing the need for manual labor. This is particularly beneficial for businesses looking to optimize their packaging line and manage high-volume demands.

Packsize machines are a game-changer in the packaging industry, offering a blend of efficiency, precision, and automation. They help businesses save on labor, reduce material waste, and ensure that every product is perfectly packaged.

Next, let’s explore the benefits of using Packsize machines and how they can transform your packaging process.

Benefits of Using Packsize Machines

Reduced Labor

One of the standout benefits of using a Packsize machine is the significant reduction in labor. These machines automate the entire packaging process, from cutting and creasing to sealing and labeling. This means fewer workers are needed to operate packing stations, allowing businesses to reallocate labor to other critical areas. For instance, the X7® can produce 1,020 boxes per hour, or one box every 3.5 seconds, eliminating the need for manual intervention.


Packsize machines offer a cost-effective solution for businesses. By creating right-sized boxes on demand, companies can minimize material waste and reduce shipping costs. This is particularly important as shipping costs continue to rise. Additionally, the machines can be integrated into existing warehouse management systems (WMS), further streamlining operations and reducing overhead costs. The subscription model for Packsize equipment also means little to no upfront capital investment, making it easier for businesses to adopt this advanced technology.

Sustainable Packaging

Sustainability is a major focus for many companies today, and Packsize machines deliver on this front. By producing right-sized boxes, these machines use less corrugated material, which means fewer trees are cut down. Moreover, the corrugated material used is recyclable and made from responsibly managed renewable resources. This reduces the need for void fill, which often ends up in landfills. As Rod Gallaway, CEO of Packsize International, points out, “When items are perfectly packaged in a right-sized carton, it makes for a great experience to open up the carton,” enhancing customer satisfaction and encouraging repeat business.

Optimized Packaging Throughput

Packsize machines are designed to handle high-volume demands efficiently. For example, the X5® can produce up to 600 boxes per hour, making it ideal for lean manufacturing environments. This optimized throughput ensures that businesses can meet their packaging needs even during peak seasons. The integration of PackNet® Cloud software also facilitates streamlined workflows, ensuring that the entire packaging process is as efficient as possible.

Reduced DIM Charges

Dimensional weight (DIM) charges can significantly impact shipping costs, especially for e-commerce businesses. Packsize machines address this issue by creating right-sized boxes that closely match the dimensions of the product being shipped. This minimizes the empty space in each package, reducing DIM charges and ultimately saving money on shipping. As Gallaway notes, “On-demand carton creation results in cartons that form tightly around the product or products being shipped. This not only cuts material waste, but the tight fit helps with the integrity of the carton, which helps reduce damages.”

By leveraging the benefits of Packsize machines, businesses can achieve a more efficient, cost-effective, and sustainable packaging process. From reducing labor costs to minimizing environmental impact, these machines offer a comprehensive solution for modern packaging needs.

Next, let’s address some frequently asked questions about Packsize machines and clarify any uncertainties you may have.

Frequently Asked Questions about Packsize Machines

What does a Packsize machine do?

A Packsize machine automates the packaging process by creating right-sized boxes on demand. This means the machine makes custom-sized boxes tailored to the exact dimensions of the products being shipped. This reduces the need for void fill and minimizes waste. These machines are used in various industries to streamline workflows, lower costs, and increase throughput.

How much is a Packsize machine?

The cost of a Packsize machine varies depending on the model and your specific needs. Packsize offers a subscription model where you pay little or no capital cost for the equipment in exchange for a commitment to buy the corrugated z-Fold material from them. This makes it a flexible and cost-effective solution for businesses of all sizes.

How does Packsize work?

Packsize machines use z-Fold corrugated material to create custom boxes. The process begins with dimensional data, which can be input manually, with a scanner, or through an existing Warehouse Management System (WMS). The machine then cuts, creases, and scores the z-Fold to the exact specifications. This ensures each box is perfectly sized for the product, reducing material use and shipping costs.

By integrating seamlessly with your WMS, these machines automate the entire packaging process, from start to finish, making your operations more efficient and reliable.

Next, let’s look at how these machines can benefit your business.


At CFAB Global, we believe in the power of innovation to transform your packaging operations. Our Machine Reliability Program is designed to ensure that your Packsize machines run smoothly, minimizing downtime and maximizing productivity. With our program, you can expect:

  • Increased Productivity: Our machines are built for speed and efficiency, producing up to 1,020 boxes per hour. This means you can meet high-volume demands without compromising on quality.

  • Reduced Downtime: Our 24-7 support hotline and regional clusters of field service engineers ensure that technical support is always available. Most issues are resolved remotely, and if an engineer needs to be dispatched, they can be sent from a nearby location.

  • Extended Lifespan of Machinery Components: Regular maintenance and prompt technical support help extend the lifespan of your Packsize machines, ensuring you get the most out of your investment.

We also offer customized analyses of your shipping process to tailor our solutions to your specific needs. This personalized approach ensures that you get the most efficient and cost-effective packaging solution possible.

For those in the food packaging or food processing industries, we recommend exploring our solutions. Our expertise in automated food packaging equipment complements our offerings, providing a comprehensive approach to optimizing your packaging operations.

Ready to revolutionize your packaging with innovation? Contact us today for a customized analysis and discover how our Packsize machines can benefit your business.

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