At Best Buy’s e-commerce and appliance warehouse in Compton, Calif., a machine near the loading docks builds custom-sized, ready-to ship boxes at a clip of up to 15 boxes per minute. The boxes can be made for video games, headphones, printers, iPad cases — anything less than 31 inches wide.  “Most people are shipping 40 percent air,” said Rob Bass, head of Best Buy’s supply chain operations. “It’s horrible for the environment, it fills up trucks and airplanes in useless fashion. With this, we have zero wasted space; no air pillows.”

At one end, long sheets of cardboard are threaded into the system. As products arrive down a conveyor, sensors measure their size. A packing slip gets inserted just before the cardboard gets cut and neatly folded around the item. The boxes are fastened with glue rather than tape, and the machine makes a perforated edge at one end to make it easier for customers to open.

No bubble wrap or extra padding. “Many people don’t have a place to recycle, especially plastic,” Jordan Lewis, director of the Compton distribution center, said during a recent tour. “There are times you have a box that’s 10 times the size of actual product. Now we no longer have that.”

The technology, developed by Italian manufacturer CMC Machinery, is also used at Shutterfly’s warehouse in Shakopee. Best Buy has also installed the system at its regional distribution center in Dinuba, Calif., and a new e-commerce facility in Piscataway, N.J. A soon-to-open facility serving the Chicago area also will employ the technology. Officials said the system has reduced cardboard waste by 40% and freed up floor space and manpower for better uses. It also allows Best Buy warehouse workers to “cube out” the UPS trucks with more boxes, which creates a host of additional savings.

“You’re shipping less air, so you can fill up to the ceiling,” said Rhett Briggs, who oversees the e-commerce operations at the Compton facility. “You use fewer trailers and have more efficient fuel costs by reducing the number of trips a carrier has to make.” With the rise of e-commerce, global package shipping volume has risen 48% over the past years, according to the technology company Pitney Bowes.

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