How a highly automated packaging center with SAP integration was implemented in industrial logistics
In the “PACKFLOW” project, a highly automated packaging center was implemented that seamlessly combines technology, IT and logistics. With intelligent SAP integration, state-of-the-art machine infrastructure and a clear strategy, a genuine Industry 4.0 success was achieved – efficient, scalable and recognized throughout the Group as a reference.
What was the initial situation in terms of technical infrastructure and machinery?
In an industrial environment with a focus on contract logistics and outsourcing solutions, the challenge was to modernize and integrate a highly complex machine park. The existing technical infrastructure comprised 33 machines with a technical availability of over 98% – including:
- Vertical form, fill and seal systems with integrated multi-head weighing
- Semi-automated pouch packaging systems
- Cartoning modules and automated carton handling systems
- Film wrapping machines for securing loads with stretch film
These packaging systems were operated with connection data of 400V, 6 bar compressed air and 230V EDP per packing station group. The aim was to maximize efficiency, transparency and process reliability.
What were the requirements for the IT system architecture and digital process integration?
A central aspect of the project was the development of a consistent IT system architecture for the logistics center. The packaging processes were to be fully integrated into the existing SAP system landscape. The project was based on the FIST guiding principles:
The implementation included:
- Connection of all machine workstations to SAP via IDOC-based interfaces
- Real-time feedback on machine status, order progress and availability via BDE
- Integration of mobile data collection (MDC) with automated transfer to SAP EWM/ERP
- Central control station systems for controlling transport, inventory and production data
This IT integration laid the foundation for a high-performance digital supply chain with complete transparency and real-time data availability.
How was the project implemented organizationally and operationally?
The project entitled “PACKFLOW” was set up as a strategic flagship project throughout the Group. As a member of the Executive Board, Peter Zitzlsperger was responsible for overall program management with decision-making, investment and implementation authority.
The core tasks in the course of the project were:
- Overall responsibility for strategic, technical and commercial implementation
- Direct management responsibility for over 200 employees, service providers and technical partners
- Development of a scalable machine and IT system in the SAP context
- Introduction of a stringent governance structure with KPI management, QM and controlling
- Implementation of the FIST guidelines as a basis for long-term efficiency and expandability
What measurable results have been achieved?
The project achieved excellent results within a very short time:
- Investment sum: € 8.9 million (machinery, IT, infrastructure, personnel)
- Sales volume (3 years): € 39 million
- Return on investment (ROI): <5 years
- Productive operation from month 6 after go-live
Other key performance indicators:
- +25 % increase in packaging output through automation
- -30 % reduction in manual intervention in the packaging process
- <2% failure rate, packaging quality at OEM level
- Project status: successfully audited and recognized throughout the Group as a reference solution
What success factors led to the sustainable transformation?
The sustainable success of the project was based on several key principles:
- Holistic integration of automation technology and SAP systems
- Clear governance and data-based control via KPIs
- Focus on FIST guidelines as a strategic framework
- Early involvement of all relevant stakeholders including plant management
- Combination of technological know-how, logistical understanding and change management
With “PACKFLOW”, a future-proof, digitalized packaging center has been created that not only realizes efficiency benefits, but also serves as a best-practice example for Smart Logistics and Industry 4.0.
FAQFrequently asked questions about packaging automation in Industry 4.0
What is SAP-integrated packaging logistics?
SAP-integrated packaging logistics means that all packaging processes – from machine control to data feedback – communicate directly with SAP EWM or ERP. This enables centralized control, real-time monitoring and complete traceability within the supply chain.
How long does it take to implement an automated packaging center?
Implementation depends on the scope and complexity of the project. In this case, the center was fully productive just 6 months after go-live – thanks to a clear project structure, SAP expertise and early stakeholder involvement.
What are the specific benefits of automation in logistics?
Typical advantages are
- Increased customer satisfaction thanks to stable quality and fast delivery times
- Increased performance through continuous production
- Reduction of manual errors
- Traceability and transparency through digital systems
- Cost reduction due to lower personnel and rework costs
