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Seeing more polybags in your operation? Don’t be alarmed. As packaging continues to shift, here’s how you can adapt your automation. How to Stop the Ugly Parcel Problem Before It Stops You P arcel packaging continues to evolve, and so do the challenges it brings to warehouse operations.
We’re seeing a fundamental shift in how automation needs to work. And it’s not just about packaging. It’s also what’s inside. Perfume, for instance, shifts inside the container, changing the center of gravity. In a polybag, that variability gets even harder to manage during sortation. Designing with the Right Priorities When we built the Pop-Up Shuttle Diverter, we didn’t just want to make it better. We wanted to make it purpose- built. That meant: • Reliable polybag handling as the baseline, not the exception • No added complexity for upstream or downstream systems • Improved throughput, minimizing downtime and manual intervention The design eliminates roller gaps and ensures better package control, especially for soft, lightweight parcels. Our goal was to reduce jams, misroutes, and staff strain. What Often Gets Overlooked In many cases, performance issues stem not just from the equipment itself, but from how it’s implemented and maintained. One challenge we often observe in the eld is missing or unclear standard operating procedures or inconsistent adherence to machine guidelines. For example, if a system is designed to sort packages weighing 10 pounds
The biggest disruption in recent years? Polybags. Shippers are shifting to soft, lightweight packaging for cost or
sustainability reasons. But from a sorting and automation perspective, polybags come with a host of headaches: They slump, shift, catch on rollers, and often arrive with uneven weight distribution, turning a minor issue into a shutdown. When we started redesigning our diverter module at Engineering Innovation, our main goal was to build something that could handle these changes. We developed the Pop-Up Shuttle Divert module to eliminate inef ciencies with better polybag sorting and reduced dead space. Understanding the Core Problem Traditional divert modules use rollers with small gaps between them— commonly referred to as dead zones due to how often parcels get stuck there during diverting. While these gaps might seem minor, they create real problems for polybags with shifting contents. Even a slight snag can slow throughput or halt operations. To give you an idea of how critical the issue is: One facility processing primarily boxes could run about 280 packages before experiencing a machine stoppage due to misrouting. The same facility, on a job where most items were polybags, hit the same problem after just 31 packages.
and up but is routinely handling 1-pound prescription bottles or similarly lightweight items, it may not operate as intended. Ensuring that operational standards are in place and followed is essential to getting the most out of any automated solution. The Takeaway As packaging continues to shift, the need to adapt your automation strategy becomes more urgent. Whether it’s through smarter equipment or better process adherence, solving the ugly parcel problem starts with understanding what your system is truly designed to handle and where it needs support. Seeing more polybags in your operation? Let’s talk about practical ways to adapt. Reach out today.
–By Tushar Sonvani
Project Manager Engineering Innovation, Inc.
Engineering Innovation ’s dedicated team of engineers and industry experts empowers your business with innovative solutions that streamline shipping and mailing operations. Since 2006, Engineering Innovation has been a trusted partner to companies of all sizes, helping them achieve greater eciency, reduce costs, and meet ever-evolving demands. www.eii-online.com
www.eii-online.com sales@eii-online.com 765-807-0699
16 Inbound Logistics • August 2025
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