One of the key elements in achieving the most efficient and cost-effective pallet wrapping operation is the machine pallet wrap, someitmes called machine film used to wrap the pallets. Whether you are using a Noxon, Robopac, or any other pallet wrapping machine, optimising the use of film can result in reduced costs, improved load stability, and higher efficiency in your operation.
In this article, we’ll explore how to get the most out of machine film, including tips on wrapping more pallets with less film, improving load stability, and the importance of a professional packaging review to fine-tune your process.
One of the most effective ways to improve the cost-efficiency of your pallet wrapping operation is by ensuring that you are using the perfect amount of machine film, sometimes called machine stretch film for each pallet.
Machine film is one of the most overlooked cost in the pallet wrapping process, but even small adjustments can lead to substantial savings.
The key to wrapping more pallets with less film lies in the optimal setting of your pallet wrapping machine. Every robot palletwrap machine has settings that can be adjusted to get the most stretch from your machine pallet wrap.
This involves tweaking factors such as film tension, number of wraps, and overlap percentage. Many companies make the mistake of using thicker film than necessary or wrapping pallets with excessive film overlap. By reducing the film thickness (downgauging) and fine-tuning the machine settings, it’s possible to achieve the same or even higher level of load stability with a thinner, more cost-effective film.
However, it’s crucial to strike the right balance between film thickness and wrapping settings. Too thin a film could compromise the strength of the wrap and the stability of the load. Conversely, using excessive film could lead to unnecessary costs and inefficiencies.
Armour Wrap, for example, is an industry leading high performance stretch film, that works on any kind of pallet wrapping machine or robot pallet wrappers . Made from incredibly thin layers of material, Armour Wrap film has high puncture resistance, 300% true stretch (Up to 4m from 1m of film), and reduces shifting during transit.
Load stability is paramount in preventing damage during transportation. While film thickness plays a significant role, other variables such as the number of wraps, the type of stretch applied, and the film’s pre-stretch ratio also affect the stability of the load. Load instability is often caused by your stretch wrap not being stretched enough before application, resulting in further stretching as your pallet moves. This under stretch is often then overcompensated for by adding additional rotations of the pallet on the pallet wrap machine, using more material and taking more time to wrap each pallet.
An operational packaging review can help assess whether your wrapping settings are optimised for maximum load stability. A key factor in stabilising the load is ensuring proper tension during the wrapping process. Too little tension or stretching may leave the load too loose, increasing the likelihood of items shifting during transit. Too much tension can cause the film to stretch excessively, weakening its ability to hold the load together effectively.
A packaging expert will evaluate your machine settings to determine if adjustments are necessary to achieve optimal load stability without using excessive film. The expert might recommend adjusting the number of wraps or altering how tightly the film is applied, ensuring that the pallet is secured without over-wrapping it.
Downgauging, or reducing the thickness of the film, is a powerful way to reduce film costs while maintaining load stability. We have many customers who have reduced their film thickness by 14 microns, and have better performance than they ever did!
Springpack can analyse your current film, breakages and film requirements to determine if a thinner film can be used without sacrificing performance.
For businesses looking to maximise the efficiency of their pallet wrapping process, booking a Springpack Operational Packaging Review is one of the best ways to ensure you’re getting the most out of your machine film and your pallet wrappers. This review, conducted by a Packaging Expert, assesses your entire pallet wrapping operation, from pallet loading, to the type of film used.
A professional packaging review involves several steps:
Downgauging, or reducing the thickness of the film, is a powerful way to reduce film costs while maintaining load stability. We have many customers who have reduced their film thickness by 14 microns, and have better performance than they ever did!
Springpack can analyse your current film, breakages and film requirements to determine if a thinner film can be used without sacrificing performance.
We will look for areas where film downgrading, adjusting the number of wraps, or altering machine settings could lead to savings.
Based on their findings, the we provide tailored recommendations. These may include downgrading the thickness of the film, adjusting the tension or number of wraps, or even switching to a different type of film.
We will then work with you to implement new products, and offer support throughout and after any changes are made to your process.
Operational reviews are free and offer you new packaging solutions you may never have even considered, for both your machine stretch wrap, and your over all packaging operation. Efficiency is key to logistical operations, and Springpack are the experts in improving operational efficiency.
Downgauging refers to reducing the thickness of the film you’re using while still maintaining the same level of performance. It’s a technique used to decrease the cost of film without compromising load stability.
Using thinner film does mean selecting a lower gauge of film, but often isn’t optimised for your needs.
Downgauging, however, involves an optimised reduction based on the specific needs of your operation, ensuring that the film remains effective even as the thickness is reduced.
If you find that your wrapping costs are higher than expected or if pallets appear to have too much overlap or excessive layers of film, you may be using more film than necessary. A packaging expert can assess your wrapping settings, such as the pre-stretch, tension and number of wraps, to ensure that you’re using the right amount of film without over-wrapping.
Yes! By fine-tuning factors like the machine’s film tension, the number of wraps, and how tightly the film is applied, you can improve load stability without using more film. Sometimes, simply adjusting how the film is stretched or how many times the pallet is wrapped can make a significant difference in the load’s stability.
Adjustments may include lowering the film thickness (downgauging), fine-tuning the film tension, decreasing the number of wraps, or modifying the pre-stretch settings. These settings depend on the type of load, the film used, and the machine you are working with. Always keep a record of your previous settings before you make any adjustments!
It’s advisable to schedule an operational packaging review whenever there are significant changes in your operation (e.g., new types of goods being wrapped or changes in the wrapping machine). Alternatively, conducting a review every 6-12 months can help ensure you’re maintaining optimal film usage and load stability as your business evolves.
Getting the most out of your machine film is about finding the right balance between film thickness, machine settings, and the number of wraps applied to each pallet. While trial and error may lead to some cost savings, the most effective way to optimise your pallet wrapping process is by booking a Springpack operational packaging review. With the guidance of a packaging expert, you can make informed decisions that increase load stability, reduce film consumption, and streamline your entire pallet wrapping process, ultimately leading to both financial savings and more efficient operations.
Springpack are experts in packaging, from paper tape to pallet wrap solutions, we offer a full packaging service. We are stockists of Robopac and Noxon pallet wrapping machines.
If you are interested in any kind of packaging, Springpack are experts in the field. Our team of Packaging Experts have all of the answers to your packaging questions. Why not get in touch with us today?
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