CartonPack, which is commercially available with immediate effect, packs single and multiple items of different shapes and sizes into one "perfect-sized" box that is produced only for that order.

Central to the system is the VaryTote, a transport tote designed and patented by CMC that features two inner adjustable guides that are used to compact the picked items to the minimum possible volume.

The VaryTotes move on a carousel which carry full totes to the machine induct section. Once empty, the totes are conveyed to the picking area for refilling.

A 3D scanner placed in the VaryTote induct area reads the three dimensions of the order set by the adjustable guides. Boxes are formed based on those dimensions and then automatically filled and labelled for delivery.

The maximum box dimension it is possible to create with CartonPack is 800x500x350mm while the minimum box dimension is 250x150x60mm. The system is capable of producing up to 700 boxes per hour, all of varying shapes and sizes.

CMC marketing manager Tania Torcolacci said: “This system saves on shipping volumes because it creates the exact size of box needed to ship the consignment, without adding void fill materials. It’s also a sustainable solution because shipping less volumes reduces CO2 emissions.”

Other benefits of the kit include complete automation from picking to the consolidation area, labour savings and increased packaging productivity. The system also removes the need to warehouse numerous different sizes of premade boxes.

Additionally, CMC’s integrated patented Packvertizing technology enables users to personalise each box with branding and targeted marketing messages printed in full colour.

The machine, which has already been sold to two European e-commerce companies, was unveiled at an open house at the manufacturer’s premises in Città di Castello, Italy last month and will be shown again at another event at the site on 20 July.