DELIVER Asia 2026 Conference Recordings

The rapid growth of e-commerce has created a major increase in parcel volumes and packaging waste.

At DELIVER Asia 2026 in Singapore, Tania Torcolacci of CMC Packaging Automation explored how packaging innovation can address both sustainability and operational efficiency challenges in fulfilment.

According to recent European studies, around 84 million tonnes of packaging waste are generated annually in the European Union. Approximately 40% of this waste consists of paper and cardboard, with e-commerce responsible for roughly 7 million tonnes each year.

As parcel volumes continue to rise globally, reducing packaging waste has become an urgent priority for retailers and logistics providers.

Parcel delivery volumes highlight the scale of the challenge.

Recent data shows that more than 700 parcels are generated every second worldwide, while the average consumer receives around 66 parcels per year.

This enormous growth in parcel shipments places increasing pressure on fulfilment operations and packaging processes.

As a result, companies are looking for new ways to optimise packaging while maintaining product protection and operational efficiency.

Many fulfilment centres still rely on manual or semi-automated packaging processes.

In these environments, operators often select standard box sizes that may not match the dimensions of the product being shipped. This leads to oversized boxes containing empty space.

To protect items during transport, fulfilment teams must add void-fill materials, increasing both packaging costs and environmental impact.

Oversized packaging also raises the risk of product damage during transport because the product may move inside the box during the last-mile delivery process.

In addition to these operational challenges, packaging also plays an important role in brand perception.

The parcel is often the first physical touchpoint between a brand and its customer, making the unboxing experience an important part of the customer journey.

Right-size packaging technology addresses these challenges by creating packaging tailored to each individual order.

Instead of using predefined box sizes, packaging automation systems measure the dimensions of the items being shipped and create a box that fits the order precisely.

This approach eliminates empty space inside the parcel and removes the need for void-fill materials.

The benefits include:

• reduced packaging waste

• lower shipping costs

• improved product protection

• enhanced customer experience

By optimising packaging dimensions for every shipment, fulfilment operations can significantly reduce material consumption while improving operational performance.

CMC Packaging Automation has developed a range of machines designed to automate right-size packaging processes.

These systems create custom packaging directly during the fulfilment process.

CMC solutions can handle both single-item shipments and multi-item orders, automatically generating the appropriate box size based on the dimensions of the products being packed.

This technology streamlines packaging operations and reduces the need for manual intervention.

One of the company’s flagship systems is CMC Genesis, a packaging platform designed to support pick-to-pack workflows.

The system uses specially designed totes that integrate directly with goods-to-person automation systems such as AutoStore.

Items are picked directly into the tote and then automatically transferred into a packaging machine that creates a custom box for each order.

The machine scans the dimensions of the order and produces a box that matches the exact size required.

This process allows fulfilment centres to create ready-to-ship parcels without pre-consolidation, improving both speed and efficiency.

Pick-to-pack workflows eliminate the traditional separation between picking and packaging processes.

Instead of picking items into containers and then transferring them to a separate packing station, orders are packed directly during the picking process.

This reduces handling steps and simplifies fulfilment workflows.

Depending on the configuration, systems like CMC Genesis can support one-touch or even zero-touch packaging processes, significantly reducing labour requirements in fulfilment centres.

Modern fulfilment centres increasingly rely on integrated automation systems.

Packaging automation must therefore integrate seamlessly with other technologies such as:

• automated storage and retrieval systems (ASRS)

• shuttle and cube storage systems

• goods-to-person picking stations

• conveyor systems

• robotic picking and sorting solutions

CMC systems are designed to connect with these technologies, enabling end-to-end automated fulfilment workflows.

Torcolacci emphasised that fulfilment technology providers must move beyond selling individual machines.

Instead, companies need integrated solutions that streamline entire operational workflows.

Packaging automation is becoming a critical part of this transformation.

By combining right-size packaging with warehouse automation and pick-to-pack processes, fulfilment operators can significantly reduce waste, improve efficiency and deliver a better customer experience.

As e-commerce continues to expand, these integrated solutions will play a key role in building more sustainable and scalable fulfilment operations.