Ranpak enhances productivity and ergonomics with Contiweb auto-splicers
Ranpak is a leading provider of eco-friendly, paper-based protective packaging solutions, committed to minimizing the environmental impact of packaging. By offering renewable, biodegradable, and recyclable alternatives, the company helps e-commerce and industrial supply chains improve sustainability, cost efficiency, and operational performance.
With facilities in the United States, Europe, and Asia, Ranpak is dedicated to delivering high-quality solutions—including cushioning, wrapping, void-fill materials, cold chain solutions, and packaging automation equipment—at maximum efficiency to drive cost-effectiveness.
Contiweb auto-splicers play a crucial role in supporting Ranpak's pursuit of efficient, high-output manufacturing. Ranpak operates several Contiweb auto-splicers across its European production facilities in the Netherlands and the Czech Republic, where Hugo Van Ool serves as Sr. Manufacturing Manager. These facilities run 24/7 cycles to meet the high demand for paper packaging. In this challenging environment, Contiweb's auto-splicing technology is essential for ensuring continuous operations at peak efficiency.
Ranpak is a leading provider of eco-friendly, paper-based protective packaging solutions.
Ensuring maximum output in round-the-clock operations
Contiweb auto-splicers enable uninterrupted production in high-speed industrial environments by automatically changing paper reels without stopping the production process. For facilities operating around the clock, this automation is vital. Without auto-splicers, manual reel changes would disrupt operations, increase production downtime with nearly 20%, and drive up costs significantly.
By automating reel changes, Contiweb auto-splicers save significant time, ensuring Ranpak maintains high uptime and maximized output.
Reliable auto-splicing ensures smooth continuous production
Contiweb has a long-standing history of developing, manufacturing, and servicing auto-splicers since its founding in 1978, with thousands of machines installed worldwide. The latest generations of Contiweb auto-splicers, widely used in the packaging production industry, incorporate advanced horizontal festoons to enable non-stop production.
This technology briefly pauses the running web during a reel change while the festoon buffers enough paper to keep the production line running smoothly and without interruption. The auto-splicer then cuts the running web and seamlessly joins the new reel to the buffered paper web, ensuring continuous production without downtime.
Contiweb auto-splicers are renowned for their reliability. Data from installed systems demonstrate splice success rates exceeding 99.7%, virtually eliminating the risk of web breaks and significantly reducing paper waste.
Watch this video to see the splicing process in action.
A glimpse of the Contiweb auto-splicers operating at Ranpak’s production facility in the Netherlands.
Enhanced cost-effectiveness and optimized resource allocation
By minimizing downtime associated with reel changes, Contiweb auto-splicers enable Ranpak to operate at full capacity, reducing the cost per unit produced. With each minute of production time utilized effectively, the facility can reduce operational costs and optimize resource allocation.
In addition to reducing production delays, Contiweb’s automated splicing systems address another critical challenge faced by many industries: labor shortages. By automating the time-intensive task of manual reel handling, these systems lessen reliance on a larger workforce, allowing facilities to maintain high productivity even with limited staff. This is especially valuable in regions or industries where skilled labor is increasingly difficult to find or retain.
Moreover, improved efficiency from automated splicing reduces labor costs while freeing up existing employees to focus on more essential and high-value tasks, such as equipment monitoring, quality control, and process optimization. This not only maximizes the use of available human resources but also fosters employee engagement by minimizing repetitive, physically demanding tasks.
Improved ergonomics for workforce wellbeing
Contiweb auto-splicers not only enhance productivity but also improve workplace ergonomics by reducing physical strain on Ranpak’s employees. Most of Ranpak’s Contiweb systems are equipped with core chucks that assist in lifting heavy paper reels. Without these chucks, workers would need to manually insert a core shaft—often weighing over 30 kg—into the paper reel to enable lifting. This task becomes even more challenging when residual paper remains on the core, adding extra weight and increasing the physical effort required.
Van Ool highlights that ergonomic considerations are a key priority at Ranpak, which is why the company prefers Contiweb auto-splicers equipped with core chucks. “These auto-splicers offer superior ergonomics. They eliminate the need for our employees to manually handle heavy core shafts, reducing the risk of physical injuries and fostering a healthier work environment.”
Contiweb auto-splicers: vital components of Ranpak’s production process
Contiweb’s auto-splicers have proven indispensable for Ranpak, boosting productivity, reducing costs, and enhancing ergonomics across their European production facilities. By automating reel changes, auto-splicing technology allows Ranpak to maintain a high level of uptime and maximize output without interruption.
About Ranpak
Founded in 1972, Ranpak's goal was to create the first environmentally responsible system to protect products during shipment. Ranpak’s mission is to deliver sustainable packaging solutions that help improve supply chain performance and costs, reduce environmental impact, and support a variety of growing business needs globally. The development and improvement of materials, systems and total solution concepts have earned Ranpak a reputation as an innovative leader in e-commerce and industrial supply chain solutions. Ranpak is headquartered in Concord Township, Ohio and has approximately 800 employees. Additional information about Ranpak can be found on its website: www.ranpak.com.