Symbiosis of merchandise management and packaging technology

The medium-sized company Hytec-Hydraulik OHG in Helmstedt proves that capacity problems can also initiate new ways of thinking. A self-developed merchandise management system and the integration of an efficient packaging system from Automated Packaging Systems are the result.

With over 17,000 components in stock, Hytec-Hydraulik OHG, which was founded over 25 years ago, supplies users of hydraulic systems in a wide range of industries. The variety and special features of the individual hydraulic parts alone require meticulous order acceptance, invoicing, warehousing and packaging of the specific parts required by the customer - preferably within 24 hours.

Wanted: flexible merchandise management system

Against this background, two years ago the company sought more efficient methods of Warehousing and packaging with simultaneous integration into a Own merchandise management system. Managing Director Michael Georgi explains: „At the time, we had simply reached the limits of our capacity. At that time, incoming orders had to be processed using relatively inflexible programmes on a PC. In bulk, we packed our hydraulic parts in conventional zip-lock bags, which was time-consuming, and produced the individual shipping labels at great expense.“ Hytec therefore searched intensively for solutions, especially as the possibilities of e-commerce were also completely underutilised.

As is so often the case, the help came from close at hand. As a newly qualified electrical engineering/automation engineer Daniel Georgi, the brother of the company boss, is now modernising the company's merchandise management processes. Together with the management and employees, the for small and medium-sized enterprises suitable Hyreka„ merchandise management system“ developed. „First and foremost, we programmed Hyreka for mail order and online retail. However, it can also be used in other areas. That is why we are now offering Hyreka to other companies for free subsequent use on.“ The system offers easy-to-understand workflows with a high level of automation. The standard scope includes article and customer management, CRM, purchasing, sales, simple financial accounting, a report designer and e-commerce functions.

„We currently serve around 45,000 active customers and dispatch up to 2,000 hydraulic parts every day,“ explains Managing Director Michael Georgi He adds: „We were also able to reduce picking errors and significantly improve the appearance and message of the packaging of our retail products.“

Wanted: efficient packaging system

Parallel to the development of Hyreka, the company was looking for a Pouch packaging system, which was not only faster than manual packaging, but also had to have configurations and interfaces so that it could be integrated into the new logistics process. This is where Automated Packaging Systems (APS) finally came into play. The system selected together with APS PS 125 OneStep table-top packaging system A test run of this packaging system over several weeks finally convinced the management and employees. The PS 125 OneStep packs up to 15 bags per minute in continuous mode. The table-top machine only requires a footprint of 560 mm x 480 mm and weighs 49 kg.

The PS 125 can process bags with a width of 50 mm to 265 mm and a length of 100 mm to 450 mm. During the packaging process, the pouches are automatically indexed and manually loaded. The subsequent sealing of the pouches can also be triggered by an optional foot switch or automatically by preset job parameters.

Requested: Bag printing inclusive

The ordered OneStep version of the PS 125 is equipped with a integrated thermal transfer printer PH 412 for the Direct printing on the bags equipped. The printer is able to print all common barcodes including 2D codes and the UPSMaxiCode with a resolution of 200 dpi. In addition, bags can be printed with graphics, free text or consecutive serial or test numbers. The print content can be changed quickly and easily by retrieving stored content from the printer or from external databases.

Hytec-Hydraulik has developed a Own print layout with product image, product name, barcode and other detailed information. AutoLabel™ design software from APS is also available as an option to make it easier to create the label layout. The separate printing and gluing of labels previously required for the individual labelling of pouches is now completely unnecessary in Helmstedt.

Found: simple operation, convenient equipment

With the PS 125 table-top packaging system, an automatic pouch guide ensures the precise positioning of the pouches during inline printing, as well as during filling and sealing. The open loading area of the machine and a controllable sealing bar increase operating convenience, machine flexibility and operating safety. up to ten packaging orders support the quick changeover of the PS 125 to other bag formats or other products to be packaged, and the rolls of the Autobag bags can be exchanged in a few simple steps. The bags on offer are produced in standard formats or customised by APS. The bags can be pre-printed on both sides or in up to twelve colours. The Helmstedt-based company opted for bags printed in white on one side with a standard format of 150 mm x 200 mm.

Each bag is now labelled with a picture of the packaged item. The transparent back of the bag makes it easy to Content control. „The printed barcodes are recognised by all common scanners and can therefore also be processed in sorting systems,“ says IT specialist Daniel Georgi. In addition to other information, the Storage location of the article printed on it. Managing Director Michael Georgi adds: „We are highly satisfied with this solution. We will certainly turn to APS again if we need more.“ The Efficiency of logistics processes including the packaging of hydraulic products has been significantly increased at Hytec since 2015.