Case Studies

Challenge A leading Malaysian manufacturer of paper-based products was experiencing poor stretch wrap efficiency. The company was experiencing high rates of stretch film breakage, resulting in large amounts of film waste. Due to the poor film strength, the manufacturer had to run wrapping equipment at lower pre-stretch rates. The lower stretch rates resulted in damaged products during shipping and used excessive amounts of film to achieve ideal load containment.

Challenge The Distributor’s packaging solution consisted of an automated packaging line equipped with an automatic rotary arm stretch wrapper. Their heavy products and wrapping procedure were applying more tension than their stretch film could handle. The film was breaking as it stretched to the desired 250%. The film would snap as it came off the roll, or puncture and break if the wrap caught on an extruding edge. The stretch film breaks would interrupt the wrap cycle, shutting down the Distributor’s automated packaging line. The breakdowns in productivity were increasing wrap times and reducing throughput by causing a backup of […]

Challenge Respack were asked to investigate pallet instability and pallet wrap snapping issues as well as undertake a transit packaging audit.

Challenge A Taiwanese leading beverage company approached Respack with a request to increase their pallet load stability whilst not compromising their current costs.

Challenge Through the acquisition of 4 separate manufacturing plants, our customer ended up with a range of film suppliers providing a range of different stretch wrapping products on three different types of stretch wrapping machinery. Following this merge, we were approached to audit the pallet stretch wrapping usage across all four facilities to gain an in-depth working knowledge of each sites unique production processes, load profiles and stretch wrap requirements.

An existing customer spending around USD 300,000 pa on stretch film, supplying Fresh and Frozen food products into the supermarket and multiples environment.

Challenge Pallets of finished concrete blocks are stored outside and exposed to the weather for up to a year prior to use. The traditional stretch film being used was deteriorating over time causing product discoloration, load security concerns and product presentation issues.

The customer’s pallet wrapper and top sheet applicator were a bottleneck for their operation and in peak season this was a limiting factor to the production output. Due to the fact they moved in to an old building in the 1990’s and had already outgrown it, they were looking for any solutions that could either free up space or improve throughput.

The client is a market leader in Australia in the animal feed sector. They are an Xforce™ fiber-reinforced film Customer since its launch in February 2018. They pack animal feed for various livestock animals into 20-25kg polyethylene bags, loading them on to a pallet, with each pallet weighing up to 1200kg. They distribute anywhere between 100—300 pallets per day, to farms around Australia.

This customer is France’s leading food wholesaler. They supply approximately 338,000 catering businesses and 83,000 independent retailers. It operates from 132 branches throughout France and operates a national delivery service. In order to replenish its business, they pick and palletize mixed loads for distribution to its 132 branches. Picked orders are palletized and stretch wrapped in order to ensure safe delivery of product. Annually, the customer distributes over 1,000,000 pallets in this way. A recent initiative reduced total stretch film consumption from 315 tons p.a. to 130 tons p.a. yielding a film saving of 59%.

A large Japan-based ambient food manufacturer supplying product into the fast moving consumer goods (fmcg) supply chain palletises and stretch wraps product specific pallets using an automatic stretch wrapper: 94,000 pallet loads of product are manufactured annually. Utilising a new improved film the company increased the pre-stretch ratio of the machine to reduce film consumption from 22.8 tonnes p.a. to 13.1 tonnes p.a. yielding a film saving of 43%.

A large International drinks manufacturer produces around 450,000 pallets of product a year from its 3 Chile manufacturing operations and in order to cope with such high volumes of throughput it uses fully automated wrapping machines at each of its sites.