Beating the odds of “pack-to-ship” pressures
Wrapping several large
gas pump valances to a single pallet with the Yellow Jacket 110.
To boost pack-to-ship
performance regarding irregularly shaped metal fabricated and powder-coated
parts, Groveport, Ohio-based Staber Industries turned to new orbital stretch-wrap technology with the purchase of a Yellow Jacket 110®, a system
that is uniquely engineered to safely and cost-efficiently secure oversized
or odd-shaped palleted loads without bands. Staber Industries realized
a speedy return on its investment through greater productivity, minimized
labor, ease of operation and the prevention of product damage during shipment.
To maintain its diversification, more than 40% of Staber Industries' business
focuses on contract fabrication work. The rest of its business involves
producing commercial and residential laundry equipment (re-manufacturing
components from companies such as Maytag, Whirlpool and Speed Queen).
In 1994, Staber introduced its own washer, the only tumble action washer
made in the U.S. that maintains top loading convenience. To fully utilize
its production facility, equipment and man-power beyond their own production,
contract fabricating and finishing services were introduced.
Hanging small parts
for powder coating.
For Staber Industries,
its mission is consistent quality and cost-efficiency in each of its profit
centers. As its powder-coat/paint line expanded to serve an increasing
number of manufacturers, the company found a weak link in pack-to-ship
productivity. Most of its loads are bulky and irregularly shaped. Staber
needed to replace its labor-intensive steel banding method. Besides being
costly, steel banding was not able to lock down each load, allowing shifting,
sliding and costly damage during shipment. Also, traditional stretch-wrap
methods could not safely secure their odd-shaped loads. Consequently,
Staber turned to new orbital stretch-wrap technology offered by the Yellow
Boosts productivity while minimizing labor
Straight on view of
wrapping large gas pump valances to a single pallet.
was definitely a two-man operation," says Bill Staber, President.
"Now, with the Yellow Jacket 110, we have nearly tripled our pack-to-ship
productivity and we need only one man to prepare the load for shipment.
Our two-man operation used to take 15 minutes per pallet. Now our one-man
operation takes under five minutes per load. The Yellow Jacket 110 is
a big plus in getting more product out the door," he adds.
stretch-wrappers that wrap around a vertical axis, the Yellow Jacket 110
wraps around a horizontal axis. The wrapping cylinder carries a spool
of stretch-wrap on a moving dispenser. Mounted on a base, the cylinder
easily moves parallel to the forks of a forklift. The stretch-wrap is
dispensed around and under the loaded pallet, while the cylinder is manually
or automatically advanced forward across the pallet. This eliminates the
need for bands or straps to attach irregularly shaped loads to pallets.
Stretch wrapping painted
ornamental railing to a single
pallet with the Yellow Jacket 110.
“Do the math,"
says Staber. “If it takes about five minutes for one man to pick
up a pallet with the forklift, put the load into the stretch-wrap system,
wrap it, and then put the secured load in the shipping area; based on
14 loads per day, that's 70 minutes of labor costs. With the old steel
banding method, it took two men 15 minutes. That's 420 minutes or 7 hours
of labor costs. Figuring labor at a round average of $20 per hour (including
labor and benefit costs), as well as material usage, the new system allows
us to save at least $180 per day or nearly $1,000 in labor costs per week,"
It is important to conduct periodic examinations of costs per pallet,
as loads and products change over time. In addition to labor costs, hidden
costs should also be calculated. These may include costs of materials
used to protect product from being damaged by banding, and product damage
and/or injury if a band breaks during shipment or handling.
Bending and welding
services for contract customers, as well as their own washing machine
any load size & shape…without scratching the painted surface
“On the powder
coat side of our business, there are no 12-inch-square products stacked
four-wide and six-high on a skid," says Staber. “We handle
all different shapes and sizes. Things that are almost impossible to strap
down, such as wrought iron railing, fencing and gates; and the circular,
wraparound valences for gas pumps. And, the other problem you run into
is that once you paint something, it becomes slippery. You put these painted
parts on top of one another and they slide all over the place, marring
the paint job. Traditional methods simply tie the parts together, while
this orbital technology locks the products down to the pallet, which acts
as the foundation," Staber explains.
With orbital technology,
the pallet becomes the backbone of the load. This provides a superior
package over traditional wrapping methods that require more wraps and
film, but does not fully secure the load. The Yellow Jacket 110 features
a wrap tension that adjusts easily to provide a range of film stretch,
which can secure cargo of any dimension, weight or shape. "As we
expand our powder coat business, the Yellow Jacket helps us to cost-effectively
pursue more of these job-shop, custom-type projects. It definitely relieves
us of the problems involved in shipping these loads. It's peace of mind.
We don't have to worry about damage to the powder coating. We just hit
two red buttons and it's wrapped and secured through the entire shipping
process," stresses Staber.
Assembly of washing
“When the Yellow
Jacket 110 was delivered, it took all of 15 minutes to show everybody
how to use it. It is extremely easy to operate," says Staber who
particularly likes the system's operator convenience factors.
Although Staber Industries
is currently dedicating the system to one shipping area,
the Yellow Jacket 110 is designed for portability. The model 87-M can
be moved easily, on locking casters, throughout an operation and can be
plugged into any 110-volt outlet. The system works with all types of equipment
— rider forklifts and narrow aisle lifts and with a semi-automatic
model, the rider can remain on the forklift for all operations.
Because orbital stretch-wrap technology can lock down any load — standard, irregular or
oversized — the Yellow Jacket 110 is an easy, yet safe, secure and
cost-effective way to attain superior pack-to-ship performance.
Learn how the
Yellow Jacket 110® might improve your operations. Call 800-387-5001
(marketing: ext. 109; email: email@example.com).