Packaging giant Pregis has launched a new automated mailing system designed to cut packaging waste, reduce operating costs and produce precisely sized mailers for individual orders.
The Chicago-based company has unveiled the Pregis Sharp InfinX, an on-demand packaging platform aimed at retailers and logistics operators handling a wide variety of products.
The technology produces mailers tailored to each order, helping businesses avoid oversized packaging while reducing material consumption, manual handling and potentially unnecessary freight costs.
The launch expands the company's Sharp portfolio of automated mailing and bagging equipment, targeting fulfilment operations facing growing pressure to improve efficiency and control costs.
Retailers and third-party logistics providers handling products ranging from electronics and beauty items to household goods and pet supplies often face challenges in selecting suitable packaging.
Traditional packing processes can require businesses to stock numerous mailer sizes or use larger packaging to accommodate different products, increasing material use and taking up valuable warehouse space.
Pregis says the new system is designed to address these challenges by manufacturing appropriately sized mailers on demand, potentially reducing packaging inventories and associated operating costs.
The Sharp InfinX can process machinable-grade versions of the company's EverTec and Poly Lite packaging materials, offering paper, plastic and cushioned mailer options.
This allows businesses to select packaging based on product protection requirements, costs and sustainability objectives.
The system has also been designed to integrate into existing packing lines or form part of new automated fulfilment operations.
Its compact vertical design aims to simplify installation, particularly in warehouses where space is limited.
Operators can switch between packaging materials using preset settings through the machine's control interface, eliminating the need for manual tooling changes.
Pregis says the flexibility could help businesses reduce labour requirements, streamline packaging operations and improve overall throughput.
Tom Wetsch, Chief Innovation Officer at Pregis, said the launch reflected the company's focus on combining automation with advanced packaging materials.
“InfinX is an emerging platform we're building within the Sharp systems portfolio that pairs automation with advanced materials that are fit for purpose,” he said.
Wetsch added that the company was focused on helping high-volume fulfilment businesses improve operational performance through integrated technology and support services.
Pregis provides installation support, testing and validation, alongside assessments of existing packing lines to help customers integrate new equipment into their operations.
The company says the InfinX platform extends this approach by offering support throughout the implementation process, including end-to-end production line integration.
Rachell Slovik, New Product Development Director at Pregis, said the technology had been developed in response to growing challenges facing fulfilment operators.
“We were finding that more and more fulfillment operations are struggling to balance rising order volumes, broader SKU assortments and increasing pressure to control operational costs,” she said.
The system brings together expertise in engineering, materials science and packaging operations to help businesses reduce waste and improve efficiency.
“InfinX is engineered to address those challenges by creating the exact sized mailers for every order,” Slovik added.
The launch comes as businesses face increasing pressure to minimise packaging consumption and manage costs associated with extended producer responsibility (EPR) requirements.
By producing mailers more closely matched to individual products, the technology aims to reduce unnecessary material use while maintaining suitable packaging protection.
Pregis will showcase the Sharp InfinX through live demonstrations at Pack Expo International 2026, taking place from 18 to 21 October at McCormick Place in Chicago.
The system will be demonstrated at booth S-3874 alongside the company's Sharp Lynx automated bagging technology.
Visitors will be able to see the equipment in operation and explore how automated, right-sized packaging could be incorporated into their fulfilment processes.
The launch forms part of Pregis's wider efforts to develop packaging automation technologies that help logistics operators and retailers manage growing order volumes while reducing waste and controlling operational costs.