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Improving Stretch Wrap Efficiency and Consumption with Make It Right

Case Study: Alcoholic Beverage Distributor

Overview

Crawford Packaging was contacted by a distributor of alcoholic beverages that was having stretch film tearing issues. The tears were occurring during the stretching process on the Distributor’s brand-new Stretch Wrap Machine. To assess the issue and identify the problem, the Distributor contacted Crawford Packaging for a free packaging consultation. During the consultation, Crawford's Packaging Specialist introduced the Distributor to the Make It Right program. The program aims to improve stretch wrap performance and efficiency by standardizing stretch wrap processes and improving stretch wrap films. The Distributor was interested in the possible savings that the program could provide and requested a Make It Right analysis.

The Make It Right analysis uncovered that the Distributor could greatly improve their existing stretch wrap performance. Through improved gauging and wrapping standards, the Distributor could reduce film consumption, improve productivity and eliminate film breakage. With the improvements, the Distributor reduced per pack costs by $0.40. This stretch film solution resulted in an estimated annual film savings of $21,120.

multiple alcoholic beverages on store shelves

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 pallets. This backup resulted in employees waiting for the wrap to be re-clamped and the wrap process restarted from the beginning. When a wrap cycle was restarted, the process would begin again from the first wrap applied. This was resulting in pallets receiving double the amount of wrap they would normally need.

Process

Crawford’s Packaging Specialist visited the Distributor’s facility to perform a free packaging consultation. The goal of the consultation was to assess their stretch film breakage issues and existing wrapping processes. During the consultation, the Specialist introduced the Make It Right program. Make It Right aims to improve stretch film practices and standards to reduce costs. Intrigued by the possibility of an annual stretch wrap savings of up to 30%, the Distributor scheduled a Make It Right analysis on their stretch wrap packaging solution.

During the Make It Right audit, the Packaging Specialist tested three of Crawford’s Guardian Stretch Films, G60, G70 and G80. These films were tested against the Distributors existing 55-gauge, 30-inch machine film.


Guardian Stretch Film Rolls in Box

Solution

Guardian Stretch Films are Crawford Packaging’s brand of stretch films. These films ensure our clients receive the strongest, most reliable films available today. All Guardian films are custom manufactured to our exact specifications and quality standards. Guardian stretch films provide customers with high-performance stretch film options that help reduce waste and improve packaging material consumption.

Guardian stretch films offer ultra-premium one-sided cling that makes pallet handling and truck loading a breeze. High-quality resins offer up to 300% pre-stretch rates, improving film consumption rates and reducing per pack costs. Guardian films are cast films, ensuring that Guardian films are extremely clear and offer a quiet unwinding. These premium films are highly puncture resistant and provide superior force to load.


Results

The Guardian G70 stretch film has helped the Distributor eliminate downtime caused by film breaks. This has helped them to increase their packaging efficiency and increase throughput. The improved wrapping process is now shorter and reduces the time it takes to wrap a single pallet of goods. This allows the Distributor to run more pallets through the automated packaging line and improve packaging productivity.

icon for increased efficiency

Improved Throughput and Efficiency

The G70 film has helped the Distributor eliminate downtime caused by film breaks. This has helped them to increase their packaging efficiency and increase throughput. The improved wrapping process is now shorter and reduces the time it takes to wrap a single pallet of goods. This allows the Distributor to run more pallets through the automated packaging line and improve packaging productivity.

Icon of Leaves to Represent Reducing Waste and Cost

Reduced Stretch Film Consumption and Improved Per Pack Costs

With a stronger film preventing wrap breaks, pallets are no longer receiving double cycles. This has helped to prevent the wasteful wrapping of skids. The Guardian G70 Film’s high-quality resins produce superior containment force and reduce the number of wraps required per pallet. The Distributor has now dropped the weight of wrap used per pallet by 21%. This reduction in materials reduces the Distributors stretch wrap costs by $0.40 per pallet.

Icon of Blue Piggy Bank to Represent Saving Money

Improved Labour

With the elimination of film breakages, the Distributor increased labour efficiency. When breaks previously occurred, the automated packaging line would shut down. An employee would then need to follow proper safety procedures to enter the line and restart the wrap process. Employees are now able to work consistently through the shift without being slowed by line shutdowns.

This knowledge-based packaging solution has helped the Distributor to save an estimated $21,120 annually on their Stretch Wrap Film.

Crawford Packaging is a full-service packaging company located in London, Brampton and Waterloo, Ontario. From packaging to packaging equipment, installation and upgrades, and in-person equipment training and repair, we're focused on your business success every step of the way.