DTLR VILLA Sees Massive Savings
with a Wayne Automation Case Erector




Before Wayne, DTLR VILLA assembled all boxes by hand, and found their unable to scale up with growing demand.


Wayne Automation built and installed an automated case erector. DTLR VILLA saw immediate results both in space requirements for boxes, and for the labor needed to assemble those boxes.


This popular retailer has already saved $350,000 with the new case erector, and the savings continue to grow.

Popular Shoe Retailer Saves $350,000 With a Wayne Automation Case Erector Machine

Lifestyle retailer DTLR VILLA had a problem. Each day, employees would assemble all boxes for shipment by hand. However, with more and more new orders coming in constantly, they were not able to work fast enough to keep up with demand. “We would be making a surplus of boxes to make sure we have enough crates and it does not create a bottleneck,” explains DTLR chief financial officer (CFO) Phil Villari. This created huge inefficiencies in space, materials, and time.

As a lifestyle retailer dealing with high-end streetwear brands, they needed a process that would allow workers to move quickly without wasting resources, and without compromising the quality of the packaging. This is when they considered a case erector machine from Wayne Automation.

Overcoming Concerns

While there was a clear motive for automation, CFO Villari initially had concerns. He worried that a machine would not work and would only incur additional labor charges. These are common concerns for companies considering automation, and a major reason smaller companies are less likely to invest. Fortunately, a referral from a corrugated box salesman led Villari to Wayne Automation, and the rest is history.

Automation Makes This Shoe Retailer a Safer, Happier Workplace

DTLR VILLA is a large footwear and apparel retailer specializing in premium brands. With 250 stores in 20 states, this is a big company with a lot of orders to fill. They recognized that in order to keep up with the ever-increasing demands, they needed to update their packaging process. To do this, they selected a custom case erector from Wayne Automation.

Today, they enjoy a less crowded, more efficient workplace thanks to the power of packaging automation. They aren’t alone either. End-of-line packaging automation is becoming sought-after technology in many industries, as companies look to cut costs and increase efficiency

The Benefits of Advanced Case Erectors from Wayne Automation

Saving Time and Resources

The implementation of the case erector saw immediate results both in space requirements for boxes, and for the labor needed to assemble those boxes.

“We used to have 4 people and now there is just 1 person operating the machine,” Villari explains. “This resulted in a 50% labor savings, which equals $50,000 per year.”

Giving Wins to the Workers

Even as impressive as that figure is, the benefits go on. Employee satisfaction has increased thanks to the speed and efficiency delivered by the box-making machine.

“They LOVE it,” Villari says. “The case erector makes their jobs so much easier and overall they are very pleased with the machine.” By eliminating the need for the difficult manual labor of assembling boxes, DTLR created a far better work environment while saving tens of thousands of dollars per year.

Automating with Care

Villari was also impressed with the personal touch Wayne Automation brings to their work. “They are very hands-on and take pride in the products they develop,” Villari comments.

The Wayne approach doesn’t stop at the delivery of the machine. The company works with customers to ensure they remain satisfied and get the most value possible out of their automated processes.

Long-Term Partners in Automation

For this popular retailer, many of the greatest advantages of working with Wayne Automation were only seen long after the initial delivery of the case erector machine. Villari commended the fast service, and detailed, ongoing training provided for customers.

“Wayne came out and still comes out once a month to maintain/service the machine and train employees how to address minor problems that come up, such as adding oil/glue.” He notes.

On top of training, Villari also emphasized how quickly Wayne responds to part failures. “They have a quick turnaround time so we experience little to no downtime,” he says. The immediate wins of automation are bolstered with a strong focus on longevity. By providing not only a box-making machine but continuous support and service, Wayne makes long-term partners out of clients.

Our value goes beyond excellent engineering. The quality that makes our company special is our dedication to our clients. What sets Wayne apart is the “overall dedication from the owners,” says Villari. Automating with Wayne means not only seeing incredible savings and efficiency wins, but knowing that you have a dedicated team that is as invested in your success as you are.

Are Case Erectors the Right Choice for Your Packaging Automation Needs?

Now that you know the benefits of working with Wayne, are you ready to supercharge your packaging process?

Contact us today to find out how end-of-line automation can improve your efficiency, productivity, and employee satisfaction. Join DTLR VILLA and experience the benefits of working with Wayne Automation firsthand.


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