"Netflix - Stuffed with innovation"

The third Netflix/Bronway collaboration involved automating the packing of mailing envelopes using a bespoke custom solution.

Task

Having successfully automated two stages of the Netflix process, Bronway was asked to design and build a prototype machine to automate the insertion of sleeved DVDs into their ‘iconic red envelope’.

The brief called for a machine to insert a sleeved disc into the mailer, fold it over, seal it and then apply a tab to it.

Solution

Bronway designed and built the prototype Mailer Loader (the ML1000) in just 20 weeks before installing and fully commissioning it in a further four weeks. The machine operated at a rate of 80 units per minute and this exceeded Netflix’s requirements. On the strength of the performance of the prototype, Netflix awarded Bronway a manufacturing contract for 75 production units of the ML1000.

We supplied all 75 ML1000 units on schedule, deploying them in over 30 Netflix distribution hubs across the US. Bronway also conducted extensive training programmes for Netflix technicians and operators to enable a successful transition from manual to automated mailer stuffing.

Result

From day one, and even now, years later, Bronway’s ML1000 machines continue to perform above specification and far in excess of Netflix’s performance expectations.

Our machines have even been captured in action by mainstream media, including USA TODAY. Have a look at them here:

USA TODAY Visits Netflix (1:47 to 2:08).

Netflix Distribution Mix Video (5:25 to 5:55).

Read on to see the next step in the process, processing the mailers when they are returned by the customers.