Marketing Automation Platform
They say to truly understand another’s problems you must walk a mile in their shoes. And that proverb has become increasingly true in business, where companies are innovating new and groundbreaking technology to solve unique challenges by working directly with the people closest to the challenge: The customer. Muller LCS is no exception. Years ago, it developed a very unique solution to add to its arsenal built by and specifically for Fabricators. Yellow Jacket Orbital Stretch Wrapper was originally introduced by fabricators to solve the unique challenges of securing oddly shaped, heavy loads directly to the pallet. This innovation is now considered the preferred load containment solution for fabricating industry veterans.
Why is it so effective? It’s simple. The Yellow Jacket Orbital Stretch Wrapper significantly minimizes the time it takes to wrap a load by hand. Typically it takes 2 workers roughly 10 minutes to wrap a similar load by hand. Yellow Jacket can wrap a similar load with 1 worker in 1 minute. In addition to reducing the labor required to wrap by at least 50%, Yellow Jacket also eliminates the need for other strapping materials or expensive cartons to secure loads.
And efficiency isn’t the only benefit. Yellow Jacket’s customers have reported anywhere from $20,000-50,000 dollars saved annually in labor costs alone. Factor in the increase in product integrity, reduction in material use and other hidden costs, and the savings only increase. Tightly wrapped to the pallet, the load’s ability to shift, fall or slide in transit is nearly impossible.
The Yellow Jacket effectively secures complex fabrications, metal parts and loose assemblies on a pallet while simultaneously minimizing the time and labor traditionally required to secure the load to a pallet.
Yellow Jacket’s Orbital Stretch Wrapper is available in manual or semi-automatic. The 87M requires a footprint of only about 8’x9’ and runs on 110VAC- making it easy to install in most any plant. It also wraps a standard pallet size up to 68” diagonal.
According to the Food Marketing Institute, the average number of items available in a supermarket in 2014 was over 40,000.1 Today that number is even greater. This abundant product availability and diversity poses both advantages and challenges. For the most part, the largest advantage is that it offers consumers more convenience and choice. That’s a great thing. But greater convenience and variety for the consumer creates greater challenges for the food supply chain. To say the food supply chain is extremely complex is an understatement. With safety and quality at the top of any food manufacturer or distributor’s list, multiple solutions to every day challenges must be acquired. At Muller, we have looked at solutions from so many different levels, from raw ingredients to processing and distribution and we believe the possibilities are abundant.
What the Recipe Calls For
To best understand the food supply chain, let’s start from the beginning. From milling grain that will eventually become flour to carrots picked from the farm, every recipe requires raw ingredients. And each ingredient requires special handling before it makes it to the store or food processing plant.
This is where load containment comes in. Let’s take flour as an example. As a general rule, flour is mostly bagged and those bags are heavy and cumbersome. When palletizing them for distribution, one must consider the size, weight and packaging material to ensure safe transport to the store or food processing plant. For instance, poly bags have a tendency to slip on each other when stacked. Though often secured with stretch film, the constant movement and weight of the bags can force the film to stretch, and the load can topple over. To avoid film stretching and excess waste, some manufacturers have opted to use hot melt. The adhesive is placed between layers of product - essentially gluing the bags to each other. While this option can be advantageous over stretch wrap in the case of poly bags, it presents several challenges for other packaging materials. For example, paper based bags risk tearing when the product is pulled apart. And no matter what type of packaging is used one disadvantage of adhesive is that it leaves residue behind on the packaging surface, which not only reduces brand integrity, but creates mess and the potential for food contamination both from the residue left behind as well as the heat source used to apply it.
One solution that has proved ideal in the milling and baking industry where bags are used most often, is water-based cohesive. It is stronger than stretch wrap alone and is cold-applied, making it safer than hot melt. It does not leave a sticky residue or harm packaging surfaces when unstacking/popping product apart. Water-based cohesive further allow for heavy reductions in traditional packaging -- stretch film, slip sheets, dunnage bags, corner boards and more can be virtually eliminated while maintaining proper load security. This allows for a leaner supply chain, reduces the number of employees needed to stabilize a load and reduces costs associated with excess materials.
In contrast, produce takes a different journey and growers are responsible for ensuring this key ingredient makes it through the supply chain. Since produce is typically transported in corrugated boxes, it leaves it vulnerable. For example, rain or any type of moisture on the boxes can lead to mold growth and other bacteria that can spread to the produce. Condensation is a major cause of damaged box loads. In fact, the same can be said for the flour loads above- especially paper bag loads that will get destroyed if wet.
Stretch hood technology is ideal in this situation. Particularly with “10-sided” (5 outside surfaces + 5 inside surfaces) waterproof protection, growers can ensure products remain dry regardless of storage conditions. However it doesn’t need to rain for moisture to form inside the load. Covering the product in plastic film on hot days can produce its own condensation build-up inside. Multi-layer film technology effectively manages sunlight and creates an impermeable barrier to liquids. Aside from eliminating condensation and unwanted elements from entering the bag, the technology also maintains barcode readability and prevents tears or punctures as bags are stretched over the load.
Set to Make
Once the raw ingredient has traveled safely to the food processor, it’s here the majority of food bought is manufactured and packed. However, this is also where things get even more complicated. As an example, there is a big difference between how macaroni and cheese versus ice cream is made. In addition, the pallet security demands for each greatly vary.
With millions of mac and cheese boxes packed each day, tackling high volumes requires the work from more automated load containment systems. Rotary ring technology is a common solution in high throughput environments like this. In addition, the technology can provide over 200 different wrap patterns and can start and stop anywhere on the load. The ability to pre-program wrap patterns also means various pallets can be wrapped without hesitation or operator interface. For lighter loads, like mac and cheese boxes, this advantage also enables users to add film in weak or vulnerable spots such as the middle or the top.
Dairy plants are also unique in their needs. Most plants are packed tightly with product rushing through at high speeds. The sensitivity of the product adds further complications to the supply chain. They must keep up with extremely high demands as millions of gallons of milk are sold daily in the United States alone. Ensuring products are quickly processed, packaged and out the door is essential to its shelf life. ‘Getting things done before the ice cream melts’ is no euphemism in the dairy industry. With the average dairy plant wrapping anywhere from 60-120 loads per hour, the ideal solution is automatic rotary ring stretch wrapping equipment.
This technology has been proven successful in an environment where speed, reliability as well as harsh environments are top concerns. Any machine downtime in the stretch wrapping zone can cause a myriad of problems upstream and greatly affect product shelf life.
Before any of the above items are available at the local grocery store, each typically makes one more stop at a distribution center. Grocery distributors are responsible for providing your local store with the variety demanded by its patrons and ensuring product arrives in immaculate condition.
According to the USDA, the United States throws away one-third of all the food it produces (133 billion pounds of food); and grocery stores are responsible for tossing 10% of that food.2 Grocery stores typically throw food away because it may be expired or damaged. Often, product packaging gets damaged during shipping, leading supermarkets to toss products even though the food hasn't been compromised. The stores assume, perhaps rightly, that no consumer is going to buy a dented box of cornflakes if a pristine one is right next to it.3
Of course, damage may be done once the food product arrives at its destination and it’s virtually impossible to expect all products to make it unscathed. The food distributor however, has the most arduous task of delivering the products without damage and there are many places during the distribution process where products have the opportunity to be damaged.
Let’s illustrate this process; first, the distributor receives pallets filled with items from one manufacturer (ex: mac and cheese boxes). The distributor then breaks down the load so that the boxes can be separated for each store. As mentioned before, the store provides great product diversity and the distributor will create new mixed product loads to meet varying demands. This mixed load, also known as B and C type loads, will have jagged edges / odd shapes because the stacked products are not necessarily from the same manufacturer or have similar packaging dimensions. This fact leaves stretch film vulnerable to tears. In addition, because product is pulled from multiple locations throughout the warehouse, it’s difficult to assign a single wrap zone. Workers must be able to move throughout the plant and adjust for inventory levels. The smaller available footprint and nimble distribution practice calls for an equally flexible solution.
To this end, a robotic pallet wrapper is an excellent solution for this; the speed, convenience and wrap quality of such machines make it an ideal choice to ensure proper product delivery and pallet security. Specifically, its increased product protection and wrapping consistency improves employee safety, lessens waste and significantly saves time and cost over hand-wrapping.
The next time you walk to your grocery store, think about the journey each item available has taken. Without proper load security along the way, most of those products would not have made it so far. From raw ingredients, to processing to distribution, Muller has a history of proudly protecting pallets throughout the supply chain while simultaneously reducing waste and optimizing load containment practices.
1 Source: Food Marketing Institute http://www.fmi.org/research-resources/supermarket-facts#sthash.U2nhbl7q.dpufThe
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: email@example.com, 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!
When it comes to pallet security, the right wrap places a critical role. Whether it’s a traditional hand wrap or an automated solution, selecting the proper film can ensure a secure fit and a productive process.
Finding both the right film and the proper process can save time, money and man-hours. Waste Gas Fabricating Co. used the GaleWrap film with the Yellow Jacket robotic pallet wrapper and found significant savings right away.
“We are now wrapping four skids in the time it took to wrap only one by hand,” says Kyle Cloman, President and CEO of Waste Gas Fabricating Co. “Coupled with the fact the job can be done by one employee instead of two or three, we have already seen a return on this investment and paid for it in savings.”
The value of GaleWrap as part of an automated solution is found in its trademarked Post Wrap Contraction that allows the wrap to keep contracting around the load even after it is wrapped. Because it is an oriented film, the GaleWrap film allows the pallet to be wrapped with fewer revolutions, reducing the film consumed. And since GaleWrap includes a guarantee that you will use the full roll without the roll hanging up at the end.
But even in hand-wrapping operations, GaleWrap provides significant benefits. The rolls themselves are lighter, reducing the risk of back injuries to employees. The trademarked Tug n' Snug feature ensures that with a quick tug at the pallet corners, the load will be secured. With a puncture resistant film, the GaleWrap technology is less expensive on either a cost-per-roll basis or on a cost-per-load basis.
The food distribution business is designed to value speed and secure packaging to the grocery aisle--and ultimately to the consumer. Different kinds of products present individual challenges and, as a result, different pallet management systems are required.
Macaroni and cheese is a dietary classic, and is a relatively simple product to make and package for the consumer. But because of the high volume of boxes shipped each day, the primary issue is securing the mac and cheese boxes to the pallet. Rotary ring technology is an especially effective and reliable solution here because it’s designed to handle the high volume and predictability of the packaging. In addition, the system can be programmed to manage the light weight of the mac and cheese boxes and secure weaker areas, such as the middle or the top, with the proper amount of wrap.
Ice cream, on the other hand, is not macaroni and cheese. It has a defined amount of time to be in packaging, given the unstable nature of ice cream, particularly in its relationship to temperature. You may not want your pallet wrapper operating in sub-freezing environments, but you also don’t want your frozen products to be exposed for very long.
With a need to wrap a load every minute, speed and reliability are the most important considerations. When combined with stretch wrapping equipment, the use of rotary ring technology again gets high marks in this area. With the freshness and shelf life of daily products the key factor, the fast-paced dairy industry counts on this stretch wrapping rotary ring technology to ensure that the products leave the dock and head out to the consumers as quickly and securely as possible.
It’s important to analyze the specific needs for wrapping and delivering food products. When it comes to shipping, not everything is as predictable as macaroni and cheese, and not everything is as volatile as ice cream. Everything moving through a processing plant and a distribution center does have a unique set of requirements, but there also are a wide variety of solutions to make sure each pallet gets the right wrap every time.
Corrugated boxes aren’t terribly sexy—unless your customer is counting on delivery of your products in one piece, on time and undamaged. That’s when boxes become the last critical link in your manufacturing supply chain.
Joe Albert, VP of Sales & Marketing for Signode Industrial Group noted in a recent article that the delivery stage of the product journey is every bit as critical as product design and manufacturing. “Proper material handling can vary significantly, but selecting the right solutions can ensure the upstream value is not lost during transport,” Albert said.
It’s also important to make the case packing and securing process just as efficient as the others. Whether building boxes for manual packaging, or as part of an integrated pick-and-ship system, having the right box on hand can keep the supply chain moving—and that’s a critical requirement in today’s ‘I want it now’ mentality.
Combined with products such as Muller’s orbital Yellow Jacket stretch wrapper or the high-speed Octopus series of pallet wrappers, the end of the supply chain can be secure, no matter which size box gets made.
The Octopus offers ring stretch wrapping that reduces waste while securing products to their pallets. The unique ring technology helps speed pallets through the shipping process while ensuring everything stays where it is placed. There are models ranging from 60 pallet loads per hour for low volume or precision operations to the Octopus S-series, which can deliver 150 pallets per hour provide the speed today’s high-speed supply chain requires.
Why do secure pallets make such a difference? Think of it this way: the proper palletizing of your products is the last time your team will touch your product before it heads out the door to your customers.