Inside the Biggest Packaging Automation Project in Aagard's History: Energizer's Journey to Sustainability

When Energizer set out to eliminate 2.5 million pounds of plastic from their packaging, they weren’t just chasing a trend—they were committing to a future of smarter, more sustainable operations. And for Aagard, that challenge turned into the largest, most ambitious installation in our company’s history.

This project pushed the boundaries of what is possible in packaging automation.

But this wasn’t our first rodeo. Years prior, Aagard had built multi-tray loading machines for a similar project, laying the groundwork for what was to come. When Walmart put the call out to major brands to innovate around sustainability—particularly reducing plastic in packaging—Energizer was already well on its way. They visited numerous suppliers, including us, and the moment they toured our facility and saw an existing system in action, they knew we could handle the entire scope. That visit, paired with our approach to end-to-end integration and packaging line efficiency, made a lasting impression.

By January 2023, the decision was made. Aagard would be the lead automation partner. What followed was an intense and collaborative journey.

To support Energizers requirements, Aagard designed a new case format. Its purpose it to hold the battery package in a way that ensures the batteries remain upright in a retail display environment. You'll find the patent-pending design on the shelves of many well-known retailers.

Collaboration That Changed Everything

Energizer pulled in their best minds from marketing, sales, engineering, and procurement—and we brought in ours. Together, we worked hand-in-hand, even making trips to retail stores and mock retail environments to evaluate how the new packaging would look, perform, and display. During a critical two-day session, Aagard joined Energizer to test over 80 different packaging designs.

We were looking for durability, presentation, and stability—packages had to stand upright on endcaps and pegboards, all while removing plastic without compromising consumer experience. This testing led to the creation of the new paper-based packaging format and ultimately, to the decision that Aagard would build a new generation of flexible, future-proof automation systems from scratch.

Custom Engineering for a Flexible, Efficient Future

One of the biggest breakthroughs? A system that could run Energizer’s full range of battery sizes with minimal changeover and impressive flexibility. Whether it’s a single hang-tab carton or a carton-and-sleeve combination, the new packaging system could seamlessly handle multiple formats on the same line—something Energizer had never been able to do before.

In the past, they had many machines running individual format sizes at very high speeds—but many were underutilized. Aagard proposed much fewer machines with broader format capability, higher efficiency, and faster changeovers. With Aagard's modular system, each line runs at optimal speeds and can swap formats in under an hour—sometimes even faster.

Engineering Every Detail—from Tray to Pallet

Each of the systems Aagard is delivering includes a complete lineup:

• Tray depalletizer and tray unloader with vision-guided robotics

• Cartoner with a unique tracking loader for precise, continuous-motion loading

• Delta-style sleever for both single and multi-carton packaging

• Case packer and palletizer/stretch wrapper for retail-ready final packaging

  
  

We didn’t stop there. We integrated Rockwell’s new HMI platform, Aagard’s Rapid Launch™ tech for near-instant set-ups, electronic changeover indicators from SIKO, and OTTO AMRs for material transport. Even laser coding and labeling were built in for a seamless, no-touch transition from product to pallet.

The Impact: Material Savings, Retail Performance, and Sustainability

The new packaging doesn’t just cut plastic—it optimizes everything. The cartons are stronger, denser, and stand up better than the old blister packs. Energizer now ships more product per case, reducing corrugate, stretch film, and freight costs, all while utilizing Aagard's new patent-pending case to improve shelf stability and shoppability.

Plus, the flexibility to adapt to future packaging formats means these systems are built to last decades—not just years.

A Partnership Built on Vision and Trust

Throughout the project, what stood out was the trust Energizer placed in us—and the responsibility we took in delivering. From early ideation to on-site optimization, this project pushed the boundaries of what's possible in packaging automation.

As Hugh Belgarde, Energizer’s Senior Director of North American Battery Operations, put it, “We knew we made the right call by partnering with Aagard up front—to create an automated solution that supports the future workforce while optimizing efficiency and sustainability.”

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