Unerringly into the package with Müller


Inserting systems by Müller have an excellent reputation. That is not a coincidence, but the result of consistent work in development. For the client, the investment in high quality machines made in Germany pays off in the long run.

Many probably do not even know this, but the company Arvato, a subsidiary of Bertelsmann, is behind many of the numerous products and solutions we use on a daily basis. Almost 70,000 employees conceive and realize innovative and integrated solutions for most diverse business processes along the integrated chains of service; that is done for business customers all over the world. These solutions include digital marketing, financial, CRM, SCM, and IT solutions. On average, every consumer in Germany comes into contact with Arvato eight times per day. One example can be, for instance, when a new electronic device is purchased online. Then it can happen that the distribution of the device is carried out by Arvato from the Marienfeld site.


Distribution by Arvato at the Marienfeld location

Around 100 employees at the Marienfeld site make sure that the ordered goods are delivered in a timely manner and within the shortest period of time possible. For that, the electronic device and the prepared box are initially scanned and then sent on together via a 500 m conveyor belt. The only thing still missing in the box is the corresponding packing slip that is generated individually for each shipping box. This packing slip is then added to the already scanned package by the Müller inserting system. In total, there are four of those systems at the Marienfeld site that are supplied by four dispatching conveyor belts. Each of the dispatching conveyor belt is equipped with a corresponding ID scanner to monitor the transportation route from the still open and empty package to the filled and sealed one.


Inserting system adds packing slips to the shipment

Via a box ID, the shipping box is already scanned six stations ahead of the document posting system. This signal is then transmitted to the printing system and the record that has to be printed - the packing slip - is submitted to the printer, printed, and accepted online by the Müller inserting system. On average, the record of a packing slip consists of 2 DIN A4 size pages per package. In this context, it is possible for the number of packing slips to consist of up to ten DIN A4 pages, for example, for a package with the measurements 500 x 455 x 200 mm. Each packing slip has a reading code. This code is read sheet by sheet, groups are collected in accordance with the corresponding coded information, and then folded to a DIN A5 format. To ensure that then the correct packing slip is passed on to the correct package, the box ID and the coded information of the printed packing slip are scanned and checked once more.  Only when these two sets of data match is the packing slip added to the package. If the box ID and the coded information of the packing slip do not match, an error message is generated and the seemingly flawed shipping box is rerouted through an integrated error track with the conveyor technology and sorted out. All the shipping boxes released by the system are subsequently sealed and provided with an address label for delivery.


Secure processing tipped the scales in favour of decision to invest

Marienfeld is Arvato’s third site already that has put into operation inserting systems by Müller, the specialist for flexible paper handling solutions from Kranzberg. Accordingly there are currently a total of twelve inserting systems in use by Arvato. “Based on our experience with the already existing systems and the secure processing of packing slips, we made the decision to use Müller inserting systems for Marienfeld as well,” says Norbert Lindhorst, a logistics planner at Arvato.  Another important deciding factor, apart from the secure processing and the four second cyclic output, was that at least 900 packages can be processed per hour per system. Currently about 10,000 packages are packaged and dispatched each day. While that means that not all systems are working to capacity, it is, however, thus possible for Arvato to react on very short notice and flexibly to higher numbers of shipment; in addition, it is possible to fully compensate production with the three other lanes in case one of the four breaks down. Thus there will not be any delay in delivery whatsoever.  In case that there is a malfunction, the Arvato employees can quickly and easily help themselves. “All our employees are trained by Müller on the Müller inserting systems and thus can, at any given time, rectify minor disturbances themselves,” says Lindhorst before concluding, “I am very satisfied with the cooperation with Müller, the coordination with each other is good and the implementation of the Müller inserting system has so far always worked out very well.”

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