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The End of the Line is Only the Beginning --Creating Efficiencies in Material Handling and Beyond

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.

Improving Safety 
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!

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