The overlooked first step in warehouse automation

WAREHOUSE AUTOMATION is often discussed in terms of large, visible systems. Automated storage and retrieval systems, conveyor networks, mobile robots and warehouse management software all play an important role in helping logistics operators increase speed, accuracy and resilience.

Prologis research estimates that around 30% of modern logistics space globally incorporated some form of automation in 2025, up from 20 to 25% five years earlier. The same research suggests that up to 50% of modern warehouses could adopt automation by 2035.

But not every bottleneck is large or obvious. Some of the most persistent constraints sit in small, repetitive processes that happen thousands of times a day. Carton opening is one of them.

In many logistics and fulfilment environments, inbound cartons still need to be opened manually before goods can move into inspection, decanting, storage, picking or returns processing. Operators may use knives or box cutters to open cases quickly, often while handling different carton sizes, tape positions, packaging formats and product types.

The task is familiar, but that does not make it low risk. Manual carton opening can affect throughput, labour use, product condition and operator safety. When inbound flow depends on people repeatedly cutting boxes by hand, variation can quickly enter the process.

One operator may cut more quickly than another. One box may be over-taped, another may contain goods close to the top seam. Some cartons may be easy to open, while others require additional handling, turning or repositioning. 

The safety case for rethinking manual cutting

The safety issue is also important. Health and Safety Executive guidance on manual handling of articles with sharp edges warns that these tasks can cause as many as a third of accidents among stores and warehouse staff. In a logistics environment, repeated knife use brings obvious risks, especially when operators are working at speed or dealing with unpredictable packaging.

Product damage is another concern. A manual cut that goes too deep can mark packaging, damage goods or create unnecessary waste. In sectors such as retail, e-commerce, electronics and apparel, even minor damage can affect whether an item can be sold, returned to stock or moved through the next stage efficiently.

This is why carton opening should be viewed as part of the wider inbound process. When automation is being used to improve storage, picking, sorting and despatch, why leave the first stage of inbound flow dependent on handheld knives?

Turning carton opening into a controlled process

Automated box opening provides a practical way to improve this overlooked stage of the process. Instead of relying on operators to make repeated manual cuts, an automated system can bring greater consistency to how cartons are opened.

The CASi-IBOD, or Intelligent Box Opening Device, is an inline, pass-through automated box opening system developed by CASI. The system is designed to cut cartons safely and consistently as they move through the inbound process, helping operators reduce manual knife use and create a more predictable flow of goods.

Rather than treating each carton as a manual judgement call, automated box opening introduces a controlled process. Boxes can be measured, positioned and opened in a repeatable way, helping reduce variation between operators, shifts and product lines.

This matters because inbound logistics is rarely uniform. Warehouses may receive a wide range of box sizes and packaging formats, while seasonal peaks, returns processing and promotional periods add further pressure. By standardising carton opening, downstream activities can become easier to plan, and operators can focus on supervision, exception handling and quality control.

The growth of warehouse automation does not mean every improvement has to start with the largest system on site. In many facilities, there is still value in identifying the everyday tasks that slow people down, create risk or introduce inconsistency.

Automated box opening technology such as the CASi-IBOD gives logistics businesses a way to address this hidden bottleneck. By reducing reliance on manual cutting, supporting more consistent carton opening and improving the first stage of inbound handling, operators can strengthen one of the most basic but important parts of the warehouse process.

Nigel Smith is CEO of TM Robotics, CASI’s UK and European sales partner

www.tmrobotics.com