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Improving Stretch Wrap Efficiency And Throughput With XPERT™ Power Pre-Stretch Machine Films

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.

Solution

Our Sales Officer visited the manufacturer's facility to conduct an Optimax analysis. The program included a free packaging consultation and a complete review of their existing stretch film operation. The program analyzed the manufacturer’s stretch wrap film, equipment and procedures. Our specialist worked with the manufacturer’s maintenance team to develop new stretch wrap standards and equipment settings. The team was shown what errors to watch for and how to adjust wrapper settings as needed. Following the audit, we provided the manufacturer with sample rolls of a 12um Xpert™ stretch film for testing in their facility.

Results

  • Less waste through a reduction of 64% in the amount of pallet wrap used. This means a packaging waste and environmental saving of more than 15 tonnes.
  • Less cost by using higher performance wrap and film which equated to a saving of 46%.
  • Less downtime through less roll changes. Xtend™ film on lines 1 and 2 wraps 52 more pallets per roll and Xceed™ on line 3 wraps 45 more pallets. This more than halves the operator time spent changing rolls.
  • Less stockholding required as a pallet of Xtend™ will wrap 4,278 pallets compared to 1,886 pallets.
  • Increased customer satisfaction through better presented pallets, fewer stability issues and less waste.
  • Improved productivity and happier operators. Better products performing as they should.