The craft beer industry continues to grow in large cities and small hamlets across the area, and the key to growth in this market is getting these small-batch ales, lagers and IPAs into the hands of their consumers quickly.
Signode has the industry in mind when it exhibited the Octopus 1717C automatic rotary ring load containment system at the 2018 Craft Brewers Conference to help the industry securely deliver these innovative products to consumers.
“We are always looking for ways to exceed customers’ expectations,” says Joe Albert, VP of Sales & Marketing, Global Wrapping Technology. “The Octopus 1717 is an ideal automatic machine for craft brewers looking to increase productivity without compromising space or budget.”
Beer cases are especially susceptible to damage when cases are improperly secured to pallets. The Octopus 1717C can wrap between 30 and 50 pallets an hour while providing cost savings and efficiency at both the production and delivery end of the supply chain.
“We built the Octopus 1717C to give customers all the benefits they’ve come to expect from our Octopus rotary ring stretch wrap machines in a smaller footprint while providing optimal load containment and minimizing film usage” says Albert. “It’s also a highly intuitive machine to operate and install considering its capabilities.”
Some of the savings comes from the Easy S Film Carriage, which efficiently delivers film in an ‘S’ wrap pattern that better secures the beer cases to the pallet while reducing both waste and machine wear.
By being able to manage pallets of varying sizes more quickly, craft beer brewers can have the confidence their efforts will be toasted by beer drinkers everywhere.
Dan Schmidt, Business Development Manager, Muller
Since Wal-Mart’s Sustainability Initiatives were first introduced in 2007, sustainability is a subject manufacturers find hard to avoid. For packaging manufacturers and suppliers, the added pressure to “go green” has only escalated over the years with customers unwilling to lower their expectations for them to meet varying sustainability goals. However, more companies are also realizing that implementing more sustainable practices isn’t just improving the environment, but also their bottom-line. For example, companies using petroleum based products are being greatly affected by rising oil barrel costs and have had to reduce usage to minimize costs. For stretch wrappers, these factors are all too familiar.
While packaging sustainability is predominately focused on reducing primary packaging material and increasing cube utilization, the end-of-line stretch wrapping process is critical to achieving optimum product delivery and reducing waste. As another step in the supply chain, it can’t be ignored if companies are looking to meet industry demands and achieve greater overall production efficiency. Advancements in equipment and technology are making it easier to reach sustainability goals while minimizing costs.
Reduction of materials is practiced in the name of sustainability. The reduction in primary packaging has put greater demands on stretch wrapping operations. Manufacturers are no longer just wrapping cardboard boxes of can goods. For most manufacturers, stretch wrapping has become essential for products that create unstable loads such as water bottles and open top display boxes.
As we have gone from boxes to trays to pads to nothing but shrink wrap, manufacturers have become more reliant on the end-of-the-line stretch wrap to make sure their product makes it to their customer intact and unharmed. Stretch wrapping may be the last operation before the product leaves the production facility, but it is the very first thing the customer sees when it enters their facility. Therefore, increasingly, stretch wrapping has become recognized as a critical component in making sure a product arrives in the condition intended. Most companies have already made significant investments upstream of the stretch wrapper, but any improvements (and the costs) will be wasted if the product arrives damaged.
It’s easy to understand how reducing film consumption is good for the environment. Less waste in landfills, reduced oil demands of producing plastic resins, and decreased energy costs associated with manufacturing the film are all green benefits to help meet growing sustainability initiatives. However, how to reduce film usage when stretch wrapping and avoid load damage can be challenging.
This article will provide a variety of solutions to minimize film usage, optimize load containment and improve efficiencies while at the same time, improving sustainability impact.
Thin is in
The most obvious way to reduce film consumption is to use a thinner film. However, moving to a thinner film without properly analyzing if it will work for the particular application will often result in an increase in film usage overall. In addition to the likelihood that a manufacturer has to compensate by using additional film to maintain the integrity and security of the package, a thinner film that is inappropriate for the application also creates the possibility for film breaks which will almost certainly increase overall film consumption, as well as slow productivity.
The good news is that recently several high quality, thinner films have come to market that can effectively reduce film usage without compromising the integrity of the load. Muller recently introduced the ReducerTM line of stretch films. This high strength, thin gauge film is produced using a new, proprietary formulation and compliments the proven, high quality Eliminator cast and ST blown films. When evaluating any new film, thorough testing with the new film and intended application and performing, at a minimum, an ASTM standardized force to load test is essential. Similar testing can also be performed to ensure the proper number of wraps is being applied.
Add Tension to Your Load, Not Your Work Day
An overlooked opportunity to limit waste is by applying proper tension to the load. To put it simply, most stretch wrapping machines have a tension adjustment that affects how tightly the load will be wrapped . It is important because if you don’t apply enough tension than you run the risk that the loads will topple over in transit. If you apply too much tension it can “squeeze” the film too tight around the load and damage the product or increase the probability that the film will break. When film breaks occur it is common for operators to “fix” any stretch wrapper issue by lowering the tension. In a study by Muller, a customer could see as much as a 10% increase in film usage when wrapping a load under low tension settings versus high tension settings using the Octopus wrapper. When applied to an average manufacturing scenario where 200 loads are wrapped per day, the result is nearly 1,000 lbs of film wasted annually. In a similar test using a used turntable wrapper, film usage increased 60% when wrapping under low tension compared to high. This is because under low tension you allow the film to recover and spring back, as opposed to when it is kept stretched under high tension. Spitting out film at low tension may be good for wrapping empty PET bottles that are prone to crushing under the lightest of force, but the majority of loads would be better served by allowing for optimal tension throughout the wrap cycle. By applying just the right amount of tension at various points on the load, manufacturers can rest-assured that they are reducing product damage while simultaneously lowering film costs. Instead of operating with a singular tension setting, variable tension control allows for increased tension at locations on the load that require extra hold (the base of a sturdy box) and lighter tension where reduced force is beneficial (sharp corners, the top of an open box). With the continuing changes in primary packaging design, it is crucial to have a system that offers flexibility and variability in order to optimize the stretch wrapping function.
For example, Muller not only offers variable tension control on their Octopus machines but, integrated with their OctoMAX™ system (highlighted below), they can also loads were wrapped and quickly identify where changes need to be made. The variable setting control eliminates film breaks and reduces usage by optimizing the settings based on the load configuration and containment needs. As film type, load dimensions or pre-stretch requirements change, the wireless function and monitoring system further make it easy to adjust to new settings. The wireless control also minimizes components and maintenance adding additional cost-saving benefits.
Measure, Monitor and Act
To really understand and quantify the benefits of any change made, having a way to record the performance of the film and equipment is essential. With retailers increasingly looking for proof that a manufacturer is making strides in its sustainability promise, stretch wrap equipment manufacturers are beginning to add monitoring systems to their machines that will measure and display at the HMI the precise amount of film that was applied to each and every load. Systems such as OctoMAXTM by Muller, will not only display the information at the HMI, but it will send an e-mail notification when too much film is applied and includes a secure web portal that the user can utilize to track historical trends, produce a variety of valuable reports, and help diagnose the root cause of issues.
Monitoring tools enable the user to keep a close eye on film usage and machine settings to help drive down the cost of stretch wrapping operations and simplify maintenance. It can even be utilized to compare the performance of two different types of films. As the old adage says, “What gets measured, gets done” and is a great way to ensure that the pre-stretch performance promised, is actually delivered. In addition, providing this data to customers and retailers is a great way to show that requirements are being met.
Optimize the System
True optimization and savings comes from looking at the stretch warp operation in its entirety – film, equipment and service. The return on investing in a simple service audit of your existing equipment can be tremendous. Speaking to your suppliers and finding out what upgrades are available is an essential component to improving sustainable practices.
As customer demands for greater packaging sustainability increase and rising material costs effect everyone’s bottom-line, taking a look at the entire supply chain is increasingly important. Overall, recent advancements in how the film is paid out, tension control, variable frequency drives, and wireless communication have created new opportunities to reduce film usage and improve overall efficincies, as well as reach your sustainability goals.
More than 30 years ago, the Octopus ring technology was introduced, and while the technology embraced packaging in a new way, the wrapping industry embraced the Octopus.
As Corrugated Week launched Sept. 24-27 in Indianapolis, Muller LCS featured the latest generations of Octopus technology at Booth 407. While a great deal has changed in those 30 years, value and the quality of stretch wrapping remains the focal point, and Octopus continues to be the industry leader.
From the high speed and high value of the B Series to the small footprint and big power of the C Series to the high-volume and low-maintenance S Series, the Octopus line provides the manufacturer with options that meet the changing needs of the accelerating supply chain. Each utilize the S film cartridge, which is easy to thread and helps reduce the overall cost of ownership.
Another high-volume alternative is the Muller TWIN series, which maximizes load containment while minimizing film consumption. It also features easy installation and requires a minimum amount of maintenance.
These all are important issues, because the expansion of e-commerce requires a smarter and more secure and more reliable supply chain. The automated supply chain was among the topics presented at Corrugated Week, which convenes every four years to look at the changing issues in the packaging and distribution industry,
While a great deal has changed in the industry since the last Corrugated Week, the fundamentals of high-volume pallet management remains a basic need. It’s what Octopus first wrapped its arms around 30 years ago, and this year’s convention saw the latest generation of that commitment to the industry.
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.”
Even with all the advancement in automated pallet wrapping technology, there are still times when one worker and two good hands are needed to secure a load for shipping. If the only costs involved were the worker and the film roll, the use of hand film still would be competitive.
Issues such as worker injury, damage to product from improper work practices, and film product waste is one reason companies have moved much of their pallet wrapping to automated systems.
There still is a need for hand film, however, and there are several best practices to ensure minimal damage and maximum success.
GaleWrap® film does offer its oriented film as part of its automated Wrap n’ Ship Program. But for the times when hand film is still the best solution, the technology built into the wrap does matter.
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
Michael Klear, Marketing Manager, Muller
Manufacturers are constantly charged with implementing processes that lead to greater efficiencies. From the outside, that may sound like an easy task. But on the manufacturing floor, changes to any part of the process, from the beginning of the line to the end, must be handled with care. Often that leads to “the fear factor”- the idea that changes lead to trouble. With that in mind, manufacturers need to identify ways to make changes that are easy to incorporate and choose processes that quickly and easily yield benefits.
When looking to create new efficiencies on the line, it is very common to focus upstream of the stretch wrapper. However, it is important to remember any improvements (and investments) that are made will be wasted if the product arrives damaged. Load containment is key, especially where accidents can lead to disaster for the manufacturer and end user.
Why Stretch Wrap?
Stretch wrapping may be the last operation before the product leaves the production facility, but it is the very first thing the customer sees when it enters their facility. Many manufacturers have made the transitions from boxes to trays to pads, while metal fabricators are becoming more reliant on stretch wrapping to ensure their product makes it to customers intact and unharmed. Therefore, increasingly, stretch wrapping has become recognized as a critical component in making sure a product arrives in the condition intended.
Stretch wrapping offers several unique benefits. For one, the wrap is clear, allowing the customer to easily identify the product they are receiving. Another great benefit of stretch wrap is that contents are protected from the elements. In terms of sustainability, several arguments have been made to suggest stretch wrapping uses less material than large box containment, adding strapping or other forms of pallet load packaging.
New stretch wrapping solutions are making changes to the end of the line incredibly attractive. When it comes to automating vs. hand-wrapping, automating is a clear winner in terms of productivity and there are statistics to prove it.
Reach Greater Productivity
Incorporating semi or fully automatic stretch wrap machines can significantly cut down the time it takes to secure pallet loads. When compared to hand wrap, most machines on the market today can wrap the same load at least 50% faster. However, in order to reap those equipment benefits, finding the right machine is paramount. When selecting a stretch wrap machine it’s important to first consider how many pallets you wrap per day and the type of load being wrapped. With so many different machines available, reaching your greatest potential for productivity means matching the machine to your application.
When securing oversized, oddly shaped, palletized loads, an orbital wrapper like Muller’s Yellow Jacket’s 87M orbital stretch wrapper should be considered. The 87M is a horizontally positioned stretch wrap dispenser that moves around and under a load as the Yellow Jacket is manually advanced across the length of the load. With the 87M, loads also remain on the forklift while being wrapped. Typically it takes two workers approximately 10 minutes to wrap a load by hand, while the same load can be wrapped utilizing the Yellow Jacket in 1 minute with only one worker- reducing labor by as much as 95%. These time and labor savings add up- in fact, customers have reported savings up to $50,000 annually. Yellow Jacket also eliminates the need for other strapping materials or expensive cartons to secure loads.
When wrapping anywhere from 10-100 standard loads per day, one might consider a simple turntable stretch wrapping machine. Higher volumes, requiring 30+ loads to be wrapped every hour, are better served by using more advanced wrappers like Muller’s Octopus rotary ring stretch wrapping machines. Available in many sizes and speeds, the Octopus line exceeds most volume and speed requirements, while its pre-stretch design can save manufacturers up to 25% in film usage over other wrapping machines.
While stretch wrapping equipment can significantly reduce time and labor associated with load containment, it also benefits employees’ health. With hand wrapping, employees are continuously lifting 30-50lb rolls of film every day and bending in awkward positions which can lead to back strain or pulled muscles.
In contrast, stretch wrapping equipment significantly reduces employee injury. Employees are at less risk as the equipment does most of the hard labor associated with wrapping. In addition, stretch wrap equipment can apply the right film tension and pressure to a load keeping it secure, and without product damage. The film also reduces the chance for products to shift or slide throughout handling and transportation.
Using straps or metal bands to secure loads also comes with its own risks. Not only is the process very tedious, bands can destroy the pallets and the loads. Too much tension on the strap and the bands can pop back when cut and injure employees. In both cases, the possibilities of loads shifting or sliding during transportation are also increased. With hand wrapping, a common problem is applying too much or too little film- resulting in unnecessary waste or causing load failures and transit damage. Strapping or banding is also challenging as the loads are only accurately secured at the point of contact. As mentioned earlier, too much tension on the bands and they can damage the product or pallet.
Go Ahead - Wrap it up
Stretch wrap machines come in many forms. Before selecting the right machinery, it is important to consider output, load type, labor and the packaging cost. If you are currently using straps or hand wrapping, taking a look at stretch wrap equipment can save you time and money. Speak to your supplier about your primary goals and options. If you are not sure how to improve your operations, companies like Muller LCS offer free packaging line audits/consultations to help companies understand the options available and tailor solutions to each manufacturer’s needs. So go ahead, wrap it up!