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 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.
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.