Automatic Secondary Packaging Solution for a Cement Industry Client to Eliminate Short-Packing ComplaintS

Background

A cement industry client was packaging 1 kg cement pouches into secondary bags containing 25 pouches each. The plant operated 24×7 with three shifts, relying on manual packaging.

Challenge

Manual packing led to frequent short-packing complaints from end customers:
– Count inaccuracies – Workers often packed fewer than 25 pouches (e.g., 24 instead of 25).
– Customer dissatisfaction – Even a single pouch short triggered complaints, often exaggerated as 2–3 pouches missing.
– Hidden losses – If extra pouches (e.g., 26 instead of 25) were packed, customers never reported it, leading to silent financial loss.
– Trust issues – Repeated short deliveries damaged customer trust and brand reputation.
– Verification difficulties – With huge volumes and continuous operations, physical verification of complaints was nearly impossible.

This resulted in leakages, loss of goodwill, and significant financial setbacks.

Alligator Automation’s Approach

Alligator Automation studied the problem and engineered a fully automatic secondary packaging solution with:
– Accurate pouch counting system – Ensured that exactly 25 pouches were packed into each secondary bag.
– Automation of counting & handling – Removed dependence on manual labor across shifts.
– Reliable packaging mechanism – Guaranteed consistency across continuous operations.

Solution Delivered

– Installed an automatic pouch counting and secondary packaging system.
– Achieved 100% reliable count accuracy, eliminating human error.
– Simplified operations, reduced manual intervention, and increased efficiency.

Results & Impact

– Zero short-packing complaints – Customer no longer faced disputes with buyers.
– Restored trust – Customers appreciated the accuracy and reliability of deliveries.
– Financial savings – Stopped revenue leakage from unnoticed over-packing.
– Operational efficiency – Smoothened 24×7 production with automation.
– Long-term value – Over the years, the customer consistently highlighted the reliability and impact of Alligator’s solution.

Conclusion

By addressing the root cause of counting errors in manual packing, Alligator Automation delivered a fully automated secondary packaging solution that eliminated customer complaints, restored trust, and prevented financial leakages. This project showcases how automation not only improves efficiency but also safeguards customer relationships and brand reputation.