The first consideration in any stretch wrapping operation is a secure load. Right after that comes the consideration of how much wrap material needed to secure the load.
When the Octopus ring technology was developed more than 30 years ago, it addressed both issues in a compact and efficient form. The pallet stayed in place while the stretch wrap revolved around the load, tightly anchoring the pallet and reducing worker strain.
As the technology has evolved, one of the key improvements has been the ‘S-style’ feed on the Octopus machines--from the cost-effective B-Series to the versatile C-Series to the high-speed, highly effective S-Series. The S-style feed on the Octopus accomplishes both of the goals of the original Octopus. First, it creates a more effective pre-stretch of the wrapping materials. This allows for the tightest possible wrap on the first pass, and on every pass that follows.
That’s important because not every load is a perfect cube. In an age of single-product pulls from distribution centers, it’s more likely the shipping pallet will include odd lots and different sizes and shapes of containers. That pre-stretch provided by the S-style feed gives the material handling team the confidence that every load is secured to the pallet, regardless of the size or shape of the load itself.
The other benefit of the S-style is the amount of wrapping material needed compared to the W-style pre-stretch technology. If you think about the differences between the letters, the S-style has just two pivot points; the W-style has three. Multiplied over the daily output of a stretch wrapper and the life of the product, that’s a significant amount of wrap. But because the S-style offered on the Octopus lines provides security in the pre-stretch itself, both goals can be accomplished.
The Octopus system can reduce stretch film usage by up to 25% as compared to rotary arm stretch wrap systems, and the versatility built into every Octopus system provides the greatest flexibility in wrap programs on the market.
The ‘S’ may describe the shape of the wrap form as it prepares fort secure an order, but it also stands for ‘secure’ and ‘savings’. Those are the two important considerations when considering any stretch wrapping solution.
According to the American Trucking Association1 nearly 70% of all the freight tonnage moved in the U.S. goes on trucks - which equates to 9.2 billion tons of freight annually. In short, that’s a lot of product headed to customer destinations on a daily basis and unfortunately not all arrives as intended. Nearly every manufacturer in every industry understands the importance of properly securing pallet loads for transport. One proverbial wrong turn and the entire load can be damaged.
Thankfully there are ample solutions for securing ones upstream value and ensuring products arrive as intended to their final destination. Whether a small electronic device or large industrial pipe, the first step to proper load containment is identifying the right solutions for the job. Signode Industrial Group understands this all too well. The company is made up of over 88 manufacturing facilities across dozens of industries - all focused on protective packaging and load containment needs. And if there is one thing we have learned over the years, it’s the importance of protecting customer products. Helping manufacturers better understand the supply chain and solutions available, here is a quick guide:
The first step for most manufacturers, especially in electronics, automotive and food and beverage industries, is getting product into its respective case/box. However, most cases are provided flat and must be erected, sealed and labeled before they can be unitized and shipped. Those looking for reliable, cost-effective solutions for automating these processes should consider a company like Loveshaw. As an example, their brand of Little David case forming machines are commonly integrated into existing product lines for volumes as low as 500 cases per day.
For a little extra protection inside the box, Multi-Wall is an example of a company that provides custom, eco-friendly solutions to protect products from the constant knocking and vibration caused inside the box during transportation. Products like Sus-Pak® help firmly suspend product inside the box and cushion it to prevent damage.
Once packed and sealed, the next step is pallet unitization. Those looking for proper load containment solutions need look no further than Muller. From its high speed automatic Octopus™ rotary ring stretch wrappers and Lachenmeier stretch hooders to its robotic pallet wrappers and turntables, the company provides a range of equipment and material solutions to fit various applications and budgets.
Looking to strap it instead of wrap it? Signode has long pioneered the advancement of consumables and equipment for strapping. Protecting edges from potential strapping damage, companies like Angleboard offer additional armor with cornerboards.
Further downstream, manufacturers can ensure even greater protection during transportation by reducing friction between pallet loads with Shipper Products’ airbags or slippage with AIA’s TransMat® Rubber Friction Mats. Even loads with varying temperature requirements can be safely transported with insulated bulkheads and air chutes, like those by Insulated Transport Products, which helps create multi-temp zones in single trailers.
By Neil Weisensel, Brand & Marketing Director, Muller
The way we transport products from point A to point B has changed dramatically over the years. We’ve gone from domestic railcar and trucks to worldwide air and sea shipping. While this evolution has been critical to our global economy, each stage has presented new challenges for safely securing products in transit. Since 1948, the International Safe Transit Association (ISTA) has led the industry in developing test protocols to ensure products survive the risky and hazardous global distribution market. Whether by land, air or sea, these tests allow manufacturers to predict and adjust their load containment practices to “manage risk while optimizing the supply chain.”
As a leading manufacturer of equipment and material load containment solutions, Muller understands all too well the importance of properly securing palletized units in transit. As part of the Signode Industrial Group (SIG), Muller frequently solves customer load containment challenges in the SIG Application Development and Research Laboratory (commonly referred to as the “SIG Packaging Lab”). The state-of-the-art laboratory is equipped with ISTA certified simulation equipment designed to reproduce the forces that products experience in transit.
Since “One good test is worth a thousand expert opinions!” we’ve broken down the testing process and procedures available to help manufacturers make informed decisions for current and future packaging practices.
Benefits and Timeline
As the quote above alludes, testing palletized units can save considerable time and money. Today’s laboratory testing procedures allow manufacturers to replicate real-life scenarios in a shorter timeframe. For example, a cross country journey on a truck can be replicated in a few hours on a random vibration table (explained further below). In addition, further savings can be added to the bottom line. Testing eliminates fuel, personnel and equipment needed to perform the actual journey and proactively isolates and helps solve perceived challenges.
Understanding these benefits is the first step to greater unit containment. So when is the right time to put your packaging method to the test? The simple answer is anytime: after product damage, during package redesigns, to meet customer demands, prior to product launch or to proactively test your packaging design. Ideally it’s best to test as early as possible and it’s recommended to do so during the packaging design phase.
There are a number of ways to approach testing. Three distinct approaches and services are:
1. Customer Application Review: Conducted onsite, an evaluation of current packaging methods followed by a comprehensive report of analyses and recommendations. Whether looking to upgrade a packaging system with new products or looking to identify further savings, this 1-3 day review can help.
2. Field Engineering: Services are performed onsite. It can include developing a new package or providing support through an existing project. The package can also be followed through the entire supply chain environment.
3. Packaging Laboratory Testing: Products are tested in a controlled environment on various ISTA certified equipment to ensure the packaging solution can withstand various harsh handling and shipping conditions.
Of the services listed, the most common is the laboratory testing because it is effective and efficient. It also helps prove that recommended unit containment solutions will work in the real-world. For more complex or early stage products, field testing is highly recommended. According to our laboratory packaging engineers, on average 40 hours of engineering work is required to properly test a unit. Timelines can vary based on the product conditions and testing parameters.
So what tests are available? From vibration tables to environmental chambers, there are a number of solutions available to ensure products arrive in their intended condition. The most popular test at the SIG Packaging Lab is the Random Vibration Simulation machine which reproduces vertical vibration that packaged products experience during shipping and handling. As mentioned earlier, the random vibration equipment can simulate long distance travel at a fraction of the time and cost without risk. For example, a 30 day rail car trip can be simulated on the random vibration table in just several hours. The key element to the machines’ success is a portable shock and vibration recorder equipped with a time and date stamp. The recorder collects transportation-specific data which can be replicated later on the random vibration table. In conjunction with a separate GPS system, the exact location of product impact, shock or vibration can also be determined. For products transported via ship or railcar, a Rotary Motion Vibration machine is best used to simulate its unique transportation conditions.
There are also shocks and impacts that typically occur during truck shipments and rail car coupling. An Incline Impact Machine can simulate rail car coupling and truck shocks for packaged products.
Before a palletized unit is placed on a truck or railcar it’s most likely being transported throughout the warehouse and storage yard via forklift trucks or other equipment. A Rough Handling Test can be used to recreate shock and vibration during handling.
In other instances, testing the environmental conditions of the product throughout the supply chain is most critical. This is especially true for refrigerated and frozen foods, produce and dairy applications. Whether the requirement is to test hot or cold temperatures, A Conditioning Chamber can duplicate conditions from -20 F through +100F.
When looking to test how unitized products perform when stacked or subjected to stacking weight, a Compression Test apparatus is used. This test is especially important for customers who stack settling or shrinking type units in warehouses or big box stores. In order to condition the unit for warehousing, compression strapping is recommended. A compression test can generate forces up to 20,000 lbs.
Other common tests include a Drop Test, to illustrate product performance when less than a 150 pound packaged product is literally dropped.
There will always be a need to transport goods from a manufacturer to a destination. As transportation evolves and new products are developed, testing will endure to be an effective and efficient way for ensuring properly secured packaged products as its benefits are felt throughout the supply chain. In the meantime, places like the SIG Application Development and Research Laboratory will continue to help manufactures discover more sustainable solutions for their ever-growing product protection and load containment needs.
For Muller and SIG, the future will be greater collaboration with customers to meet their unique requirements. The laboratory is readily awaiting challenges in the marketplace and will soon expand to feature all of the company’s solutions in one showroom.
To learn more, visit: http://www.signode.com/evaluation-testing/ or contact Muller directly via email: firstname.lastname@example.org, or by phone: 1-800-OCTOPUS (1-800-628-6787).
 https://vimeo.com/istavideo - Introduction to ISTA Video
 https://vimeo.com/istavideo - Introduction to ISTA Video
 https://youtu.be/eIq4tw2ceso - Signode General Applications Video
Recently, a wholesale grocery distributor took its commitment to quality products and service to a whole new level by incorporating Muller’s hand film and machine film into its supply chain operations. While film quality was critical to this expansion, it was the service, implementation and results that really sealed the deal.
Muller’s film can cost slightly more per roll than competitor’s film but the secret to beating the favored unit cost is simple; Muller proposed a long-term “partnership” and provided consistent and clear results.
Common practice to prevent damaged goods is to contain loads using stretch film. Whether by hand or machine, stretch wrapping pallet loads has been extremely effective for reducing product damage during transport.
The Challenge: To secure loads in ways that optimized the entire supply chain operation.
The grocery distributor understood this challenge and looked for ways to do just that. “Stretch film is often perceived as a basic consumable and judged solely on price per roll,” says the client. “We knew better and challenged our vendors to show us the true value and total cost of ownership.”
The first step to achieving greater total cost of ownership was understanding all the costs involved. For stretch wrapping processes, that means film consumption, labor and product integrity.
“Muller offers a quality product, we realized that right away. But more importantly, Muller provides superior service and backs up all its recommendations with real, quantifiable data. It takes the guessing game out of procurement,” says the client. “At the end of the day, determining optimal film product and application was key to our long-term savings and efficiencies.”
The distributor had data. They had answers. They had an SOP. But now the company had to implement it.
Muller representatives supported the distributor with on-site, round the clock service and support for the first week of initial delivery of film to each location. The partnership agreement with the distributor and Muller also ensures routine visits from Muller experts to any of the distributor’s DCs and requests for visits are completed in a timely fashion.
“How my product is received is just as important as the process it takes to get it there,” says the client. “Muller understands that and the result is that we are able to better serve our customers, ensure a consistent and secure pallet delivery while simultaneously saving money and reducing waste along the way. It’s really been a fantastic experience and a true partnership from start to finish.”