Case Study - TwinPrint Key in 3PL Fulfillment Line
May 15, 2025
Case Story: Streamlining Shipping at 3PL withTwinPrint®
When a major 3PL sought to streamline its packing list and shipping label process as part of their plant automation, integrator Bastian Solutions recommended FOX IV Technologies' TwinPrint® dual-sided label print and apply systems, known for their reliability and efficiency.
The Challenge and Solution
ChallengeThe end user desired an automated shipping label and packing slip system that could handle confidential information. They required a versatile solution for various box sizes and heights across two different fulfillment lines. The label needed to fit entirely on the smallest size box without wrapping over the edges.
Solution
FOX IV's TwinPrint® label print and apply systems were selected for their ability to print and apply 5 x 8 direct thermal over direct thermal labels, eliminating the need for thermal transfer ribbons, which carry user information as well as the products they use. This capability not only ensured confidentiality but also increased customer security by removing customer details and order information from the waste stream.
Implementation and Results
ImplementationThe customer purchased four TwinPrint® systems – two for redundancy – and integrated them into their fulfillment lines. The systems utilize twin Zebra printheads, simultaneously printing shipping information on the visible top side of the label and order contents underneath on the label liner. This dual-printing process guarantees matching information, reducing mismatch errors and returns.
Each fulfillment line had specific requirements. The first line, with boxes varying in height from 1.5 to 5.5 inches, required up to 10 boxes per minute to be labeled. The second line dealt with a broader range of box sizes, from 7.125” L x 9.5” W x 4” H to 23.625” L x 21.625” W x 13.75” H, also needing to label up to 10 boxes per minute. Both systems were mounted over the fulfillment lines and utilized random height sensing to apply the labels accurately.
Results
FOX IV’s TwinPrint® system provided several benefits:
- Perfect Fit - the 5” x 8” label size fit onto the smallest box size without exceeding the smallest box edges.
- Reduced waste by repurposing up to 60% of the label liner as the packing slip.
- Eliminated additional packing slip insertion equipment and plastic packing slip envelopes.
- Enabled packing slips to be applied to full-case items.
- Improved confidentiality and security with direct thermal labels.