John Johnson joined the DC Velocity team in March 2004. A veteran business journalist, John has over a dozen years of experience covering the supply chain field, including time as chief editor of Warehousing Management. In addition, he has covered the venture capital community and previously was a sports reporter covering professional and collegiate sports in the Boston area. John served as senior editor and chief editor of DC Velocity until April 2008.
These days, it seems there's no tracking problem that RFID can't solve. Need to protect vintage Jimi Hendrix rock 'n roll memorabilia (think the guitar strap immOréalized at the 1969 Newport Pop Festival) from theft or counterfeiting? There's an RFID solution for that. Want to keep close tabs on critical airplane parts to shorten service calls and reduce travel delays? There's an RFID solution for that. Looking to track supplies being shipped out to troops in Iraq? There's an RFID solution for that too.
Though it may have gotten off to a bumpy start, the RFID revolution is clearly upon us. In just a few short years, RFID has grown into a multibillion dollar industry. ABI Research projects that spending on RFID software and services alone will hit $3.1 billion this year. But perhaps more astonishing than the growth itself is who's profiting from the boom. It's not always the big, well-established companies that are raking in the RFID revenues. In many cases, it's small venture-funded companies barely out of the startup phase.
In the brash young RFID technology market, it seems the old rules no longer apply. It used to be that when a company opened discussions with a potential new supplier, one of the first questions it asked was how long the vendor had been in business longevity generally being equated with reliability and fiscal soundness. Nowadays, it doesn't appear to matter. Up-and-coming players some of which were running their businesses out of a garage just a few years ago are landing big contracts with the likes of Boeing and the U.S. government.
You don't have to look far for examples of small and nimble RFID startups that have edged out their larger rivals. Last May, Dulles, Va.-based ODIN technologies beat out a roster of veteran players including IBM for a $14 million contract to outfit 69 Defense Logistics Agency facilities with RFID readers. A month earlier, in April 2006, San Jose, Calif.-based newcomer Intelleflex inked a multimillion dollar deal with Boeing to supply RFID tags for parts for its 787 Dreamliner jets when they go into production this year. Boeing, which is paying approximately $20 per tag, expects to use more than a million tags annually once production begins.
What sealed the deal in this case was Intelleflex's product the industry's first fully integrated multi-protocol EPC-compliant RFID single chip IC. In the passive operating mode, tags made with this battery-powered chip offer a read range of more than 300 feet and a full 64 kilobytes of user read/write memory. Though Boeing invited all of the major RFID players to bid on its smart label contract, the Intelleflex tag was the only one able to meet the aircraft maker's memory requirements.
"That shows the value of innovation," says ODIN's president and CEO, Patrick Sweeney, referring to the Intelleflex RFID chip. "Those guys built a better mousetrap."
For Boeing, the chip's technological advantages evidently outweighed Intelleflex's lack of experience the company received its first venture funding in 2004 and is just ramping up production of its first product. "Boeing is more innovative and venturesome than most big companies," says Bob Pavey, an investor with venture firm Morgenthaler and a recent appointee to the Intelleflex board. "Boeing recognizes more than most companies that much of the technology they will need in the future will not come from the large suppliers."
Magnet for talent
Better mousetraps aside, another factor that sometimes works to the startups' advantage is their willingness to take on the smaller contracts that large corporations might not consider worth their while. That gives them a foot in the door, not to mention a big in with the customer later on if that pilot progresses to a rollout.
"Some of the smaller integrators aren't so averse to take a $200,000 contract when an IBM might be looking for more lucrative, longer-term deals," says Michael Liard, principal analyst for the RFID practice at ABI Research. "But guess what? Those smaller guys taking those little deals have gained a host of experience around RFID deployment, and have gained a competitive advantage in the process."
That's no small consideration. In an industry where expertise is in short supply, experience with RFID deployment can translate directly into more business. Sweeney, for example, credits his company's experience with deployments for its roaring 400-percent annual growth rate. "We're having much better success than I ever thought we would," he says. "I think that's because of the lack of expertise with this technology."
At the moment, the smaller companies have what amounts to a monopoly on RFID talent and expertise, says Daniel Engels, former research director for the Massachusetts Institute of Technology's Auto-ID Center. "All of the innovative work that has come out lately has come from small companies moving into the space," says Engels, who is now an associate professor in the University of Texas's electrical engineering department. Though that's not uncommon in the tech sector, he adds, "I would say the trend is probably extra pronounced for RFID. RFID is unique in that the real expertise exists in all the small companies right now."
Part of the explanation lies in the simple fact that the smaller companies are the ones with the jobs. From the large corporations' point of view, the RFID market is still too small to justify devoting a lot of bodies to it.
And even when large corporations like Texas Instruments do venture into RFID development, there's no guarantee that they'll be able to sustain the momentum once the development process concludes. "When TI was developing its SpeedPass solution, their head count was up," says Engels. "But most of their technical people left after that, during the period when they were not innovating, and went to companies like Matrics [which has since been acquired by Symbol] and other smaller companies that were doing more innovative RFID work."
Brain drain
It's not just technical people who have fled to the smaller companies. Top executives have joined the exodus as well. Take Rich Bravman, the former CEO of Symbol Technologies, who defected to Intelleflex in September 2005. Bravman, who is now CEO of Intelleflex, was Symbol's fifth employee when he joined the firm as a software developer back in 1978, shortly before the company landed a $5 million contract with the Defense Department.
For Bravman, the opportunity to try to repeat that success at Intelleflex proved irresistible. "It was a very comparable situation," he says of his early days at Symbol. "We were a new company at the time and the hand-held laser scanner was a brand new concept and a new technology. The competition included mega companies like NCR and IBM, but we emerged the winners based on having a technology that nobody had figured out how to do. By the time I left, we were a $3.5 billion company. I very much hope we have the same success trajectory here."
Symbol isn't the only company whose management ranks have suffered casualties. In June 2005, RFID hardware specialist Sirit hired Norbert Dawalibi away from Psion Teklogix, where he had been president and CEO, to be its new CEO. In October, Sirit recruited former Texas Instruments RFID guru Tony Sabetti to be vice president of RF solutions.
ODIN, too, has succeeded in luring some top talent away from the competition. Diana Hage, who headed up IBM's RFID and wireless division, defected to ODIN this fall after the company beat out IBM for the government business. "That's been a spectacular hire," says Sweeney. "It has given us a lot more insight into how the bigger companies are addressing the market."
Deal or no deal?
Now that they've been lapped by the competition, can the larger companies ever expect to catch up? Some say the only way for the big guys to make up the lost ground is to acquire those smaller firms that have been landing the fat contracts. Sweeney says he receives buyout overtures frequently.
The market has already seen some mergers and buyouts like Sirit's purchase of TradeWind Technologies and SAMSys last year, and Symbol's acquisition of Matrics in 2004 (before Symbol itself was bought by Motorola last September). But Sweeney thinks the real action will begin when the market matures, most likely in 2008.
"I think one thing you'll see is a company like Texas Instruments asking 'How is this [startup] company beating us on these deals?'" says Sweeney. "Their mentality will be, 'We'd better buy them before they beat us again.'"
The Boston-based enterprise software vendor Board has acquired the California company Prevedere, a provider of predictive planning technology, saying the move will integrate internal performance metrics with external economic intelligence.
According to Board, the combined technologies will integrate millions of external data points—ranging from macroeconomic indicators to AI-driven predictive models—to help companies build predictive models for critical planning needs, cutting costs by reducing inventory excess and optimizing logistics in response to global trade dynamics.
That is particularly valuable in today’s rapidly changing markets, where companies face evolving customer preferences and economic shifts, the company said. “Our customers spend significant time analyzing internal data but often lack visibility into how external factors might impact their planning,” Jeff Casale, CEO of Board, said in a release. “By integrating Prevedere, we eliminate those blind spots, equipping executives with a complete view of their operating environment. This empowers them to respond dynamically to market changes and make informed decisions that drive competitive advantage.”
Material handling automation provider Vecna Robotics today named Karl Iagnemma as its new CEO and announced $14.5 million in additional funding from existing investors, the Waltham, Massachusetts firm said.
The fresh funding is earmarked to accelerate technology and product enhancements to address the automation needs of operators in automotive, general manufacturing, and high-volume warehousing.
Iagnemma comes to the company after roles as an MIT researcher and inventor, and with leadership titles including co-founder and CEO of autonomous vehicle technology company nuTonomy. The tier 1 supplier Aptiv acquired Aptiv in 2017 for $450 million, and named Iagnemma as founding CEO of Motional, its $4 billion robotaxi joint venture with automaker Hyundai Motor Group.
“Automation in logistics today is similar to the current state of robotaxis, in that there is a massive market opportunity but little market penetration,” Iagnemma said in a release. “I join Vecna Robotics at an inflection point in the material handling market, where operators are poised to adopt automation at scale. Vecna is uniquely positioned to shape the market with state-of-the-art technology and products that are easy to purchase, deploy, and operate reliably across many different workflows.”
Third-party logistics (3PL) providers’ share of large real estate leases across the U.S. rose significantly through the third quarter of 2024 compared to the same time last year, as more retailers and wholesalers have been outsourcing their warehouse and distribution operations to 3PLs, according to a report from real estate firm CBRE.
Specifically, 3PLs’ share of bulk industrial leasing activity—covering leases of 100,000 square feet or more—rose to 34.1% through Q3 of this year from 30.6% through Q3 last year. By raw numbers, 3PLs have accounted for 498 bulk leases so far this year, up by 9% from the 457 at this time last year.
By category, 3PLs’ share of 34.1% ranked above other occupier types such as: general retail and wholesale (26.6), food and beverage (9.0), automobiles, tires, and parts (7.9), manufacturing (6.2), building materials and construction (5.6), e-commerce only (5.6), medical (2.7), and undisclosed (2.3).
On a quarterly basis, bulk leasing by 3PLs has steadily increased this year, reversing the steadily decreasing trend of 2023. CBRE pointed to three main reasons for that resurgence:
Import Flexibility. Labor disruptions, extreme weather patterns, and geopolitical uncertainty have led many companies to diversify their import locations. Using 3PLs allows for more inventory flexibility, a key component to retailer success in times of uncertainty.
Capital Allocation/Preservation. Warehousing and distribution of goods is expensive, draining capital resources for transportation costs, rent, or labor. But outsourcing to 3PLs provides companies with more flexibility to increase or decrease their inventories without any risk of signing their own lease commitments. And using a 3PL also allows companies to switch supply chain costs from capital to operational expenses.
Focus on Core Competency. Outsourcing their logistics operations to 3PLs allows companies to focus on core business competencies that drive revenue, such as product development, sales, and customer service.
Looking into the future, these same trends will continue to drive 3PL warehouse demand, CBRE said. Economic, geopolitical and supply chain uncertainty will remain prevalent in the coming quarters but will not diminish the need to effectively manage inventory levels.
In a push to automate manufacturing processes, businesses around the world have turned to robots—the latest figures from the Germany-based International Federation of Robotics (IFR) indicate that there are now 4,281,585 robot units operating in factories worldwide, a 10% jump over the previous year. And the pace of robotic adoption isn’t slowing: Annual installations in 2023 exceeded half a million units for the third consecutive year, the IFR said in its “World Robotics 2024 Report.”
As for where those robotic adoptions took place, the IFR says 70% of all newly deployed robots in 2023 were installed in Asia (with China alone accounting for over half of all global installations), 17% in Europe, and 10% in the Americas. Here’s a look at the numbers for several countries profiled in the report (along with the percentage change from 2022).
Sean Webb’s background is in finance, not package engineering, but he sees that as a plus—particularly when it comes to explaining the financial benefits of automated packaging to clients. Webb is currently vice president of national accounts at Sparck Technologies, a company that manufactures automated solutions that produce right-sized packaging, where he is responsible for the sales and operational teams. Prior to joining Sparck, he worked in the financial sector for PEAK6, E*Trade, and ATD, including experience as an equity trader.
Webb holds a bachelor’s degree from Michigan State and an MBA in finance from Western Michigan University.
Q: How would you describe the current state of the packaging industry?
A: The packaging and e-commerce industries are rapidly evolving, driven by shifting consumer preferences, technological advancements, and a heightened focus on sustainability. The packaging sector is increasingly prioritizing eco-friendly materials to reduce waste, while integrating smart technologies and customizable solutions to enhance brand engagement.
The e-commerce industry continues to expand, fueled by the convenience of online shopping and accelerated by the pandemic. Advances in artificial intelligence and augmented reality are enhancing the online shopping experience, while consumer expectations for fast delivery and seamless transactions are reshaping logistics and operations.
In addition, with the growth in environmental and sustainability regulatory initiatives—like Extended Producer Responsibility (EPR) laws and a New Jersey bill that would require retailers to use right-sized shipping boxes—right-sized packaging is playing a crucial role in reducing packaging waste and box volume.
Q: You came from the financial and equity markets. How has that been an advantage in your work as an executive at Sparck?
A: My background has allowed me to effectively communicate the incredible ROI [return on investment] and value that right-size automated packaging provides in a way that financial teams understand. Investment in this technology provides significant labor, transportation, and material savings that typically deliver a positive ROI in six to 18 months.
Q: What are the advantages to using automated right-sized packaging equipment?
A: By automating the packaging process to create right-sized boxes, facilities can boost productivity by streamlining operations and reducing manual handling. This leads to greater operational efficiency as automated systems handle tasks with precision and speed, minimizing downtime.
The use of right-sized packaging also results in substantial labor savings, as less labor is required for packaging tasks. In addition, these systems support scalability, allowing facilities to easily adapt to increased order volumes and evolving needs without compromising performance.
Q: How can automation help ease the labor problems associated with time-consuming pack-out operations?
A: Not only has the cost of labor increased dramatically, but finding a consistent labor force to keep up with the constant fluctuations around peak seasons is very challenging. Typically, one manual laborer can pack at a rate of 20 to 35 packages per hour. Our CVP automated packaging solution can pack up to 1,100 orders per hour utilizing a fully integrated system. This system not only creates a right-sized box, but also accurately weighs it, captures its dimensions, and adds the necessary carrier information.
Q: Beyond material savings, are there other advantages for transportation and warehouse functions in using right-sized packaging?
A: Yes. By creating smaller boxes, right-sizing enables more parcels to fit on a truck, leading to significant shipping and transportation savings. This also results in reduced CO2 emissions, as fewer truckloads are required. In addition, parcels with right-sized packaging are less prone to damage, and automation helps minimize errors.
In a warehouse setting, smaller packages are easier to convey and sort. Using a fully integrated system that combines multiple functions into a smaller footprint can also lead to operational space savings.
Q: Can you share any details on the typical ROI and the savings associated with packaging automation?
A: Three-dimensional right-sized packaging automation boosts productivity significantly, leading to increased overall revenue. Labor savings average 88%, and transportation savings accrue with each right-sized box. In addition, material savings from less wasteful use of corrugated packaging enhance the return on investment for companies. Together, these typically deliver returns in under 18 months, with some projects achieving ROI in as little as six months. These savings can total millions of dollars for businesses.
Q: How can facility managers convince corporate executives that automated packaging technology is a good investment for their operation?
A: We like to take a data-driven approach and utilize the actual data from the customer to understand the right fit. Using those results, we utilize our ROI tool to accurately project the savings, ROI, IRR (internal rate of return), and NPV (net present value) that facility managers can then use to [elicit] the support needed to make a good investment for their operation.
Q: Could you talk a little about the enhancements you’ve recently made to your automated solutions?
A: Sparck has introduced a number of enhancements to its packaging solutions, including fluting corrugate that supports packages of various weights and sizes, allowing the production of ultra-slim boxes with a minimum height of 28mm (1.1 inches). This innovation revolutionizes e-commerce packaging by enabling smaller parcels to fit through most European mailboxes, optimizing space in transit and increasing throughput rates for automated orders.
In addition, Sparck’s new real-time data monitoring tools provide detailed machine performance insights through various software solutions, allowing businesses to manage and optimize their packaging operations. These developments offer significant delivery performance improvements and cost savings globally.