At Brainard Rivet, we are always looking for ways to improve our processes, enhance efficiency, and ensure the safety of our team. That’s why we are excited to unveil our latest investment in automation: a fully integrated, start-to-finish automatic packing system that transforms how we handle packaging and shipping on the shop floor. This upgrade brings major improvements in safety, organization, and productivity.
A Much-Needed Upgrade
Our previous packing process was entirely manual, requiring our team to hand-form each box, staple the bottoms, and then carefully stage them for packing. This method was not only time-consuming but also took up valuable space, often leading to an unorganized staging area. In addition, our existing packing machine was one of the oldest pieces of equipment in our plant, requiring frequent repairs and presenting safety concerns for our operators.
The introduction of the new automatic box erector marks a significant step forward. With this upgrade, we are eliminating inefficiencies, reducing physical strain on our workers, and improving the overall safety of our packaging operations.
How the New System Works
Our new system features a seamless, automated workflow that drastically reduces manual labor and enhances accuracy:
- Flat Box Loading – Operators load flat cardboard blanks into the box maker, which automatically forms and tapes the box bottoms.
- Hydraulic Bin Dumper – Parts are loaded into a hydraulic bin dumper, which transfers them into a hopper with no heavy lifting required.
- Automated Filling – The system accurately dispenses parts into each box by either weight or piece count, offering flexibility for order requirements.
- Vibratory Settling Table – Once filled, the box moves to a vibrating table that settles the contents to ensure optimal packing.
- Automated Top Sealing – Boxes are then indexed through an automatic top taper that seals the top of the box securely.
- Final Palletizing – At the end of the line, a team member stacks the finished boxes on a pallet and applies the appropriate labels.
The Benefits of Automation
This new system brings a range of benefits that will positively impact our operations:
- Enhanced safety – The old system posed several safety hazards, requiring frequent repairs and maintenance. The new machine eliminates those concerns, providing a safer work environment for our team.
- Increased efficiency – Automating the box formation, packing, and sealing process reduces manual labor, allowing our team to focus on other important shipping tasks.
- Improved organization – With no need to pre-stage assembled boxes, our workspace will remain more organized and efficient.
- Better productivity – This system allows us to complete our daily workload faster, freeing up time for our team to assist in other departments, such as roll sorting and washing/cleaning parts.
- Greater accuracy and flexibility – The ability to pack by both weight and piece count provides more control over inventory and order fulfillment.
Looking Ahead
Thanks to this new piece of equipment, we are already seeing a significant improvement in daily operations. The automatic box erector is cutting a few hours off the workload by eliminating the need for manually making boxes.
Todd Carr, Brainard Rivet’s newest employee-owner and packing operator, has been working at the new machine and experiencing these benefits firsthand. Todd started on January 6, 2025, and in just six short months has earned the respect of his teammates and managers alike. He brings a positive energy and a can-do attitude to everything he does—qualities that have made him a fantastic addition to the team. Todd shared, “The new pack station is a blessing. It saves 3–4 hours of manual labor. I appreciate how much easier it makes my job.” Derek Morrison, Project Engineer, adds, “Once fully optimized, this new equipment will not only allow us to pack more efficiently, but also provide us with the flexibility to focus on other key areas within the shipping department.”
At Brainard Rivet, we are committed to continuous improvement, and this new automated packaging equipment is just one example of how we are evolving to meet the needs of our customers while maintaining a safe and efficient work environment. We look forward to seeing the positive impact of this upgrade and continuing to explore new technologies that drive innovation in our operations. Stay tuned for more updates as we continue to enhance our manufacturing processes to better serve our customers and our team!