Disconnected systems and manual processes create silos between production and the warehouse, leading to inventory inaccuracies and space-intensive products clogging the floor. Clarus WMS centralises inventory control, providing real-time scan verification and directed logic to optimise space and ensure full batch traceability from raw material to finished goods.
In many packaging operations, the warehouse and the production line operate from different data, leading to a breakdown in operational flow. When materials are issued to production manually or finished goods are only entered into the ERP hours after they have been palletised, the system is always behind the reality of the floor. A modern WMS changes this day-to-day performance by providing a single source of truth that updates in real-time as barcodes are scanned.
Better control looks like an operation where operators no longer spend time searching for pallets and production teams never wait for stock updates. By removing these silos, organisations are rewarded with higher throughput and the ability to scale without adding administrative headcount. You gain the ability to manage bulky, space-intensive containers and packaging products with precision, ensuring that space is utilised effectively rather than being dictated by guesswork or “tribal knowledge”.
Ultimately, the shift from manual to digital processes removes the hidden costs of labour inefficiencies and picking errors. Whether you are a manufacturer moving finished goods to a B2B wholesale client or a 3PL provider managing multi-client packaging stock, Clarus provides the discipline needed to meet tight delivery windows and rigorous customer audits.
For packaging firms serving food or pharma sectors, compliance is non-negotiable. Clarus automates batch tracking from raw material intake to finished goods, ensuring you can perform full recalls or audits in minutes rather than days.
Packaging products are bulky and space-intensive. Our logic directs operators to the most efficient storage locations based on size and velocity, maximising your cubic capacity and reducing forklift travel time.
Eliminate manual entry errors and paper pick lists. Every movement (from the production line to the loading dock) is verified via barcode scanning, ensuring 100% shipping accuracy for your B2B wholesale clients.
Perfect for converters and manufacturers, this feature manages the marriage of various components into finished SKUs. Maintain absolute inventory accuracy for both components and final packaging units in one system.
Plaspac, a provider of custom plastic packaging solutions, found themselves in a position common to many high-growth manufacturers: their manual processes could no longer keep pace with their expanding order book. Operating with paper-based systems meant they lacked the real-time visibility required to manage a busy warehouse floor effectively.
By implementing Clarus WMS, Plaspac moved away from manual updates and disparate data sources. The system allowed them to synchronise their warehousing and distribution activities, providing the scalability needed to handle more complex client requirements. The introduction of real-time scan verification ensured that stock accuracy improved significantly, reducing the time previously wasted on manual stock takes and error correction.
With the WMS in place, Plaspac successfully transitioned into a more agile and thriving warehousing business. They gained the ability to provide clients with the stock certainty and traceability required in the modern packaging industry. While specific percentage improvements are confidential, the primary result was a reduction in administrative overhead and a warehouse that could finally support, rather than hinder, their continued growth.
Most packaging manufacturers already rely on an ERP or a production-focused system for their core business logic. Clarus is designed to complement these systems rather than replace them, acting as the execution layer on the warehouse floor. Integration is typically handled via our robust API or structured file exchanges, ensuring that when finished goods are scanned into the warehouse, the ERP is updated immediately. This removes the “silos” mentioned in our brief, where production and warehouse teams work from different data. [Assumption: integrations would be handled via standard API protocols, subject to the specific capabilities of your existing ERP vendor]. By automating this data flow, you eliminate manual double-entry and ensure that sales teams are selling from accurate, real-time stock levels.
Traceability is a non-negotiable requirement when supplying containers and packaging for cosmetics, pharmaceuticals, or food. Clarus uses Batch Lot Control Logic to ensure every item is tracked from the moment raw materials arrive to the point the finished product is dispatched. The system maintains a digital audit trail of every movement, touchpoint, and transformation. This means that during a customer audit or a potential recall scenario, you can generate a full traceability report in minutes. Our barcode scanning and serial number capture features ensure that no item moves without being recorded, providing the “bulletproof” compliance evidence that high-value customers in regulated industries demand. It essentially turns a high-stress manual audit process into a simple, automated report.
The timeline for going live depends on the complexity of your operation, such as whether you are a single-site manufacturer or a multi-site 3PL provider. [Estimate: a typical Clarus WMS rollout takes between 12 and 16 weeks from initial scoping to go-live, depending on integration requirements]. We prioritise a phased approach that minimises disruption to your production lines. The process begins with a detailed discovery phase to map your current floor flows, followed by system configuration, staff training, and a controlled “go-live” period. Because Clarus is highly configurable, we can often adapt the software to your specific bulky-product handling rules without the need for lengthy custom coding, which significantly accelerates the deployment compared to traditional “big-box” WMS solutions.
Transitioning from paper to a digital WMS for Packaging & Containers is as much about people as it is about technology. We focus on creating intuitive HHD (Hand-Held Device) workflows that guide operators through their tasks with clear, step-by-step instructions. This removes the “tribal knowledge” barrier, where only a few long-term staff members know where certain stocks are hidden. By providing real-time feedback and scan verification, the system gives staff more confidence that they are doing the job correctly the first time. Training is hands-on and focused on the practical reality of your warehouse floor. Most operators find that once the initial learning curve is over, the reduction in manual paperwork and the elimination of “pallet hunting” makes their daily work significantly less frustrating.
ROI in the packaging sector typically comes from three main areas: labour efficiency, space utilisation, and error reduction. By eliminating manual stock checks and “searching time,” you can often increase the throughput of your existing team by 20% or more. [Estimate: many clients see a full return on their investment within 12 to 18 months through saved labour costs and reduced waste]. Additionally, by using Directed Putaway Logic to better manage bulky containers and packaging, you may find you can defer expensive warehouse expansions by getting more stock into your current footprint. The reduction in “mis-picks” and shipping errors also saves significant costs in redelivery and customer credits, while the ability to prove traceability can help you win larger, higher-margin contracts from regulated industries.
Clarus is a hardware-agnostic platform, meaning it is designed to work with a wide variety of industry-standard Android-based hand-held scanners and tablets. If you already have a fleet of modern scanning devices, we can typically deploy the Clarus application directly onto them. If you are starting from scratch, we can provide guidance on the best ruggedised devices for a packaging environment where dust and high-volume movement are factors. The system also supports various label printing requirements, allowing you to generate GS1-compliant labels or customer-specific packaging labels directly from the warehouse floor. This flexibility ensures that you are not locked into a single hardware vendor and can scale your device fleet as your operation grows across multiple sites.
