Boosting Pallet Wrapper Efficiency to Cut Costs for a Top Canned Food Manufacturer
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REJUVENATING PALLET WRAPPING MACHINE FOR OPTIMAL PERFORMANCE
A market-leading canned food manufacturer was experiencing multiple issues with their pallet wrapper, causing large volumes of wasted film and increased costs.
The wrapping machine was using insufficient quality film which had a noteworthy influence on end-of-line packaging operations, as it caused the wrapping to snap and therefore not effectively secure pallets. Our knowledgeable load containment expert diagnosed the issue, which was that the film was sub-par, and the gearing of the machine could be changed to increase efficiency further.
THE REPERCUSSIONS
- The company was wasting large quantities of stretch film, as the film kept snapping repeatedly.
- There was a large amount of bypassing, where the film may slide or slip off the load during transport or handling, leading to potential damage or instability.
- Environmental impact – Significant amount of wrapping wasted.
- Machine downtime leads to wasted labour and time, due to an increased number of changeovers.
- Financial losses accrue from damaged and wasted wrapping materials.
Once our load containment expert identified the problem, a solution was efficiently and quickly found that would cost-effectively address the client’s problems. The two-step solution for their problems began with using a different film, KwikFilm® high-performance machine film by Kwikpac. This film offers outstanding performance, substantial waste reduction, significant savings, increased load stability, increased stretch capacity, and increased tension capability. The increased tension and better cling of the KwikFilm® meant that less changeover occurred and no more bypassing or film snaps.
The second step of the solution was to up-gear the machines to a 270% level to increase the savings further. The machines were previously geared at 180%, turning 1.00 metre of film into 2.80 metres. By gearing the machines to 270%, every metre of wrap is stretched to 3.70 metres, increasing the tension, reducing the film needed to wrap a pallet, and saving the client over £90,000+ a year in stretch film cost alone. The savings are further increased when you consider the lack of downtime with no film snaps or bypassing issues occurring.
Our solution delivered tangible benefits, including improved efficiency, productivity, and cost reduction. Testimonials from the client underscored the positive impact on their operations and bottom line.
ENVIRONMENTAL BENEFITS
The carbon footprint & water reduction is significant. We reduced:
Miles per truck by 37,469 miles
Tours around the world by 1.50
Large fuel tankers full of water by 163
(Based on 1.15kg/mile average truck CO2 Emission levels and the capacity of a 38,000L large fuel tanker.)
By offering a 360° solutions service we are putting the needs of our customers at the core of our business with a strong focus on meeting their product & machinery needs, and helping them to save more and waste less.
We present a solutions-based approach, allocating a dedicated account manager, who will put together solutions, detail upfront costings & fully engage with you to understand your challenges.
