In the lighting sector, packaging presents numerous challenges: high dimensional variability of products, a very large number of item codes, and the need to guarantee fast, Just-in-Time deliveries. Traditional management of pre-made packaging generates high warehouse costs, slows down processes, and requires the purchase of large batches of die-cut boxes, often not aligned with actual consumption.
Philips Lighting Case Study: choosing a packaging machine to make the packaging process more efficient
When Philips Lighting turned to Panotec, the company had the following objectives:
- Need for high flexibility in handling a very diverse product assortment
- Just-in-Time production to support fast logistics
- Approximately 1,700 different products to be packaged
- Minimum order of die-cut boxes: 3,000 pieces, not compatible with real consumption
- Excessive warehouse space dedicated to packaging storage
- 68 box formats with consumption below 300 pieces/year
- 105 box formats with consumption below 3,000 pieces/year
- Significant storage cost: €0.07 per box per day
Philips Lighting installed a high-performance packaging machine integrated with a complete waste-management system and two gluing machines.
This configuration now enables the production of custom-sized boxes in real time, completely eliminating the need to keep a large stock of packaging in the warehouse and freeing up numerous pallet positions.
Thanks to the Panotec solution, Philips Lighting achieved:
- Elimination of reorders for 175,000 boxes
- Elimination of low-consumption formats
- Release of numerous pallet positions in the warehouse
- Average savings of 60% by switching from die-cut boxes to Box On Demand
- Reduced seasonal impact on cardboard availability
- Reduced purchasing and warehousing costs
- Calculated ROI: 11 months