Flat polybags are widely used to package small parts—but as volumes increase, manual bagging often becomes one of the most expensive and inconsistent steps in the operation.
At Kyana Packaging Solutions, we evaluate polybag operations through the Kyana Packaging Assessment (KPA). For many high‑volume users, the KPA reveals that automated bagging is no longer a capital expense—it’s a cost‑reduction strategy. As part of the KPA, we assess whether automatic bagging equipment such as Autobag® systems from Sealed Air can improve throughput, labor utilization, consistency, and total packaging cost.
We frequently see the following with manual or semi‑manual bagging operations:
Manual bagging works at low volumes—but at scale, it often creates hidden operational cost.
The Kyana Packaging Assessment (KPA) provides a structured way to determine when automation makes sense—and when it doesn’t.
1. Volume & Throughput Analysis
The KPA evaluates:
Relevant insight:
Operations packaging hundreds or thousands of small parts per shift often reach a break‑even point where automation reduces cost faster than labor optimization.
2. Labor Cost & Utilization Review
The KPA examines:
Common finding:
Manual bagging consumes labor that could be reassigned to higher‑value work once automation is introduced.
3. Bag Size Standardization & Film Optimization
Manual bagging often relies on:
The KPA evaluates:
Automation advantage:
Autobag systems use the right‑sized bag—often reducing film usage.
4. Packaging Consistency & Seal Integrity
The KPA assesses:
Automation benefit:
Automated bagging delivers consistent seals and bag presentation—reducing quality variation tied to operator technique.
5. Scalability & Future Growth Evaluation
The KPA looks beyond today’s volume: -Expected growth rates -New product or SKU introductions
Key insight for decision‑makers:
Adding labor scales linearly. Automation scales exponentially.
Where Autobag® Systems Fit Within the KPA
When the KPA indicates automation is viable, Autobag® bagging systems from Sealed Air are often evaluated due to their fit for:
Autobag systems support:
Importantly, the KPA determines fit first—the equipment supports the strategy, not the other way around.
Building the Business Case: Automation vs Manual Bagging
Through the KPA, we quantify:
For many customers, automation:
Typical KPA Findings
Small Parts Distributor – High SKU Count
Manufacturer – Seasonal Volume Swings
Outcome: Improved responsiveness without adding headcount
Why Use the KPA Before Automating?
✅ Confirms automation makes financial sense
✅ Prevents over‑ or under‑specifying equipment
✅ Aligns automation with actual part mix and volumes
✅ Creates a defendable ROI story
✅ Ensures packaging materials and equipment work together
The KPA ensures polybag automation is engineered and justified—not assumption‑driven.
If your operation relies heavily on manual flat polybagging for small parts, the Kyana Packaging Assessment (KPA) can determine whether automation will reduce cost, improve throughput, and support future growth.
Contact Kyana Packaging Solutions to evaluate your polybag operation and determine if automated bagging—such as an Autobag® solution—fits your business.