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Eliminating Hidden Waste with Wrap It Right

Case Study: Manufacturer

Overview

A Niagara Region manufacturer’s stretch wrapping solution was hurting their bottom line – and they didn’t even know it. The manufacturer was sold a 30-inch stretch film by a supplier after being told it would offer secure load containment. What they didn’t realize was that each pallet was wrapped with too much stretch film, increasing their overall film consumption.

A Crawford Packaging Specialist was originally called in to speak to the manufacturer about upgrading their stretch wrappers to keep up with increased production. However, after conducting a Wrap It Right audit, the Specialist determined that a smaller film width and a specialized stretch wrapper would save the manufacturer thousands per year on film costs. The Specialist recommended using an 80-gauge, 20-inch UVI film and a Wulftec SML 150 with extended height. This solution would not only upgrade their packaging operations, it would also save the manufacturer an estimated $1,200 per machine.

Once a trial machine was implemented with the recommended features and film specifications, the manufacturer immediately began to see results. Film consumption and waste have dramatically decreased as a result of the new stretch film, and the extended height has reduced the previously large overhang on top of the skid. As a result of the success, the manufacturer is upgrading all four of their production lines with the solution, boosting their savings to $4,800 per year.

man holding clipboard next to stretch wrapped pallet

Challenge

A manufacturer was using outdated stretch wrappers and the wrong stretch film for their pallets, resulting in increased film consumption. Pallets leaving the facility had excessive wrapping and a large overhang on the tops of skids — something the manufacturer thought was necessary for load containment. The manufacturer knew they needed to upgrade their stretch wrappers to keep up with demand.


Process

Originally called in to recommend new stretch wrappers, it was during a Wrap It Right audit the Packaging Specialist noticed a stronger solution. The Wrap It Right audit revealed that the 30-inch film being used was too wide, and could be cut down by a third to save money without sacrificing load containment strength. Paired with the new stretch film, a Wulftec SML 150, equipped with extended height, could wrap pallets faster and reduce film consumption.

wulftec sml 150 turntable stretch wrapper with safety barriers

Solution

Wrap It Right

Wrap It Right audits and reviews existing stretch film practices and equipment to identify inefficiency. Wrap It Right will increase productivity and reduce costs through standardization of stretch film practices. Through Wrap It Right, clients have realized savings up to 30% on their annual stretch film costs.

Wulftec SML 150 Semi-Automatic Turntable Stretch Wrapper

The Wulftec SML 150 is an efficient alternative to manual stretch wrapping solutions. Using a one-sided cling stretch film, the SML 150 eliminates the issue of parts sticking together in transit. Chosen for its ability for efficient and consistent performance, the Wulftec SML 150 is an ideal option when considering stretch wrappers.


Results

The manufacturer has realized savings upwards of $4,800 per year on stretch film costs alone. On top of that, the increased performance of their new stretch wrap solution provides reliable throughput in their packaging process.

solid blue icon of a garbage can

Reduced Stretch Film Waste

The new, 20-inch stretch film reduced the amount of extra film overhang on top of the pallets. This has created for less waste while achieving strong load containment.

icon of blue plug with leaf

Reduced Consumption

The manufacturer consumes far less film with the Wulftec SML 150 and 20-inch stretch film. Fewer rolls are needed in their day-to-day, which helps them achieve savings of $1,200 per wrapper annually.

icon of piggy bank

Reduced Labour

By switching to 20-inch stretch film, labour has also seen positive change. Previously, the heavy 30-inch film was difficult to change over on the stretch wrappers. Now, thanks to the lighter film, changeovers are faster and easier.



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.