Packaging isn’t just a step in the shipping process — it’s a strategic opportunity. As e‑commerce and distribution networks expand, the need for efficiency and sustainability grows right alongside them. Continuously Variable Packaging (CVP) delivers both.
CVP technology automatically creates a right‑sized box for every order, on demand. Instead of relying on a set of predetermined stock box sizes, each package is built precisely to fit the product inside. The result: less waste, lower costs, and a better customer experience.
Originally developed under the Sparck Technologies brand, CVP systems are now part of the Packsize portfolio — bringing together automation, sustainability, and proven performance in right‑sized packaging.
CVP systems take a simple idea and turn it into an advanced packaging solution: the best box is the one made for the product.
Using continuous corrugated material (also known as fanfold corrugated) the CVP machine scans each order, then automatically cuts, folds, and seals a custom box in real time.
Here’s the process in action:
1. Scan and measure: The system captures precise item dimensions (including single or multi‑item orders).
2. Custom box creation: It forms a box that fits those measurements exactly, using only the material required.
3. Seal and label: Each box is closed securely, weighed, and labeled for shipment — ready to move in seconds.
A single CVP system can produce up to 1,100 right‑sized boxes every hour. That speed allows operations to scale efficiently while maintaining packaging accuracy and product protection.
Traditional packaging often means shipping products in oversized boxes filled with void fill. That inefficiency adds cost in the form of excess material as well as freight, but it also has a negative environmental impact.
CVP systems – as well as Packsize’s broader range of automated packaging solutions – eliminate those challenges by producing the perfect box every time. Businesses benefit through:
Reduced shipping costs: CVP technology lowers shipping costs by creating a right‑sized box for every order. Because each package is made to fit the exact dimensions of the product, there’s no wasted space — and that means lower dimensional weight charges from carriers.
Improved efficiency: Automation accelerates throughput, which speeds up order fulfillment and frees up labor resources. This benefit results in lower per-order handling costs.
Less packaging material: Each box uses only the amount of cardboard needed. This eliminates excess corrugated and filler materials, which reduces cost.
Lower carbon footprint: By optimizing the packaging to use the exact amount of material required, you are able to lower transportation emissions. In addition to cost savings, this lowers your carbon footprint to support sustainability goals.
Enhanced customer experience: Orders arrive in compact, protective packaging that reflects your brand’s commitment to smart shipping.
Now part of the Packsize portfolio, CVP technology expands what’s possible in automated packaging. Together, we help fulfillment operations transition from fixed box inventories to fully automated, sustainable packaging systems.
Whether you’re shipping hundreds of parcels a day or managing high‑volume distribution centers, Packsize solutions powered by CVP automation enable smarter, leaner, and more responsible packaging performance.
Discover how CVP and Packsize’s right‑sized packaging technology can reduce waste, cut costs, and improve your fulfillment efficiency. Contact Us to speak with a packaging automation expert today.
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