Service Success Story- Strapping Machine

Service Success Story- Strapping Machine

Faulty machinery is a real pain in the back! That was certainly the case for a Chicago-area canned food manufacturer whose inline pallet strapper broke down. Material handlers had resorted to manually palletizing and banding layers upon layers of heavy cans. As a result of the broken strapper, production at this facility was reduced by 50%.

That was when the discomforted cannery called the toll-free number for Best Packaging and scheduled a diagnostic appointment for the same day. When the technician arrived, he received background information from the support engineer and immediately began troubleshooting. He noticed the feed module’s motor was spinning, but the module was not feeding.

Usually, the most obvious answer is the correct one, but this was the exception that proves the rule. Typically, when technicians receive a feed error, it indicates a faulty feed module. The support engineer certainly suspected so and was surprised when Best Packaging discovered the real issue. What couldn’t be seen with the naked eye, was that the motor was not fast enough and could not pick up enough torque to feed properly. The feed module itself worked fine, but the board supplying current to the feed module was at fault. The feed module was not receiving enough current.

New parts for their board were required to remedy the inline strapper and alleviate the employees. With Best Packaging’s expertise, the right part was quickly identified, and they coordinated the order directly from the equipment manufacturer. The strapper was transported to Best Packaging’s workshop at the request of the customer to streamline their production area in the interim. The support engineer, line supervisor, and all the laborers at the cannery grew eager for the new parts to arrive as their team began to experience ergonomic constraints from manually pushing pallets.

Finally, new parts for the board arrived at Best Packaging’s workshop. Because the machine was already there, technicians could complete the installation of new parts quickly, without having to schedule a service visit.

With Best Packaging’s help, this purveyor of canned goods regained 100% productivity and put an end to their sciatic saga. Malfunctioning equipment is not always what it appears to be, so next time faulty packaging equipment has you puzzled (or even pained) call the packaging equipment specialists at Best Packaging: 888-930-BEST

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November 16, 2016 | Design - Innovation - Inspiration - Packaging Equipment - Stretch Wrap - Technology - Testing | No Comment

My Thoughts On The PACK EXPO 2016

Although the packaging industry is working hard to maximize technology use, I believe there is still more that can be done. After attending the PACK EXPO, here’s are my thoughts…

I noticed the majority of stretch wrap machines were all very similar- following standard practices with a few minor modifications here and there. Many of the demonstrations utilized square uniform loads that are easy to wrap. However, not much was conveyed regarding what could be done for random pallet’s that have sharp points everywhere as these pallets make film selection a critical step in this packaging process.

This got me thinking… what developments should we be looking out for in the near future for odd-shaped loads? What is it going to take for things to change within the industry? What kind of creative thinking needs to happen to break the mold? What needs to happen in the packaging industry to unleash innovation that the industry hasn’t seen in years?

Over the years, I’ve noticed the packaging companies that succeed are the ones constantly testing and monitoring their wrap parameters. When dealing with stretch film, if you’re not occasionally monitoring what you’re doing, damage goes up. But how does one do that? How do we monitor and determine wrap parameters beyond a square load? When it comes to wrapping loads, why work in a flat world if the packaging isn’t?

In an era where computerization and data collection have become the ‘must-have’ elements, the installation of 3D modeling for the purposes of data collection has the potential to revolutionize the quality at which tasks are performed. With live data being fed from their equipment into a computerized system, workers are more capable of selecting the proper film type, gauge, and number of wraps a particular load requires. Rather than having to manually adjust the machine according to the size and product, incorporating 3D pallet sensor technology would enable you to record the shape, weight, and type of product to get a better understanding of what stretch wrap settings to employ. Incorporating a 3D Pallet scanner would provide an immediate overview of all production parameters and data that needs to be done based on the load. Thus, I see the future of stretch wrapping being very data-driven. I envision exploiting sensor technology to obtain data points that enable workers to make better informed decisions for their stretch wrap settings.

As an ASTM member, I plan on utilizing these insights to develop unique solutions in the market. With one patent approved for a pallet parking system and one patent pending for the SPYDR multi-wrapper system, Best Packaging aims to continue to innovate and offer the Best solutions to our customers. For more information, give us a call at (888) 930 BEST.

-Steve Kudia

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November 2, 2016 | Packaging Standards - Stretch Wrap - Technology - Testing | No Comment

ASTM Packaging Committee To Revise ASTM International Standard

Steve Kudia, Owner of Best Packaging, serves on the ASTM committee that writes the standards guide for selection and use of Stretch Wrap Films titled D4649. This committee recommends guidelines and test methods for the selection, specification, and use of stretch wrap films for unitizing, reinforcing, and palletizing (ASTM, 2009). This includes storage and/or transport in warehouses, truck trailers or rail boxcars, and other transfer terminals. The purpose of this committee is to evaluate how stretch film is applied to a unit load, its application in transport packaging, ways to test and improve packaging efficiency while saving time and money. As an ASTM member, Steve Kudia is part of a prestigious worldwide network of technical experts. His aim is to make sure processes stays efficient by monitoring trends and educating customers on how they can improve their supply chain performance.

The committee is currently working to revise the ASTM International standard, ASTM D4649, for the 2017 publication. For more information on ASTM testing standards, give us a call at (888) 930 BEST

October 24, 2016 | Preventative Maintenance - Reducing Cost - Stretch Wrap Machine - Technology - Testing Equipment | No Comment

The Importance of a Good Factory Acceptance Test (FAT)

As with any machine, there is a tendency for stretch wrap results and accuracy to drift over time. In order to be confident that your stretch wrappers are operating properly, there is an ongoing need to service and fine-tune equipment for reliable, accurate, and repeatable applications.

Just a little bit of attention can go a long way. For instance, many in this industry agree that implementing regular maintenance is less stressful and expensive in preventing problems than interrupting a job to repair them. Thus, it is highly recommended that manufacturers execute a Factory Acceptance Test (FAT). A FAT is a series of tests and inspections that identify any problems or issues with the machine and ensures that equipment meets the standard requirements for production, configuration, and sustainability.

In order to get the most out of these inspections, companies need to complete a performance test with packaging materials used in the production line to assess the function and integrity of the machine. The machine will not perform efficiently if the criteria aren’t specified; therefore, you must use the appropriate gauge and film for your stretch wrapper. If you’re unsure of the appropriate stretch wrapper settings for your application, let us help measure how much gauge and containment force your load needs. We’ll make certain to educate your employees operating the production line.

A few checks on a weekly basis can keep your machines running smoothly and help you catch potential problems before they happen. For more information on how to get the most out of your FAT, contact us at (888) 930 BEST.

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October 11, 2016 | Equipment Sales - Helpful Tips - Packaging Equipment - Reducing Cost - Reducing Damage - Stretch Film - Stretch Wrap Machine - Stretch Wrappers - Technology - Work Injuries | No Comment

Signs Your Business Could Benefit From A Stretch Wrapper

It may seem like a good decision to hold off on making a large investment, however future downtime could end up costing you more than you think. If you are experiencing any of this in your wrapping process, it may be a wise decision to make a stretch wrap machine purchase.

You’re wrapping more than 20 pallets a day. It would probably be in your best interest to get a stretch wrap machine because of the manual labor that is involved with hand wrapping. A large amount of bending and twisting is required in making sure that the entire pallet is wrapped thoroughly. The amount of physical work involved takes a lot of energy that employees will need throughout the day. A stretch wrap machine would not only speed up the process, but also free up the employee to accomplish other tasks while the pallet is being wrapped.
You’re experiencing load damage because of improper wrapping. In order for stretch film to work properly, it has to be stretched 70-80% of its ultimate stretch. Ultimate stretch is what helps to hold pallet loads in place. When wrapping pallets by hand, it is difficult to consistently reach the amount of required stretch which could potentially lead to products falling over and cost more money.
Stretch film costs are becoming too high. It is quite uncommon for workers to reach maximum stretch potential. which results in a lot of money being wasted on excess stretch film. However, with a stretch wrap machine, you’re able to boost the stretch rate and eliminate unnecessary extra revolutions of film being applied which could reduce costs.
You’re having issues with employee safety. An automatic stretch wrapper would keep a forklift operator on the forklift which is could be an important safety advantage. Not to mention, a poorly wrapped pallet can fall over, resulting in damaged goods or injury to a handler. A stretch wrap machine could ensure worker safety by properly wrapping loads in a timely manner.
You encounter inconsistent output. An operator who wraps pallets with hand wrap stretch film is not able to wrap every load exactly the same way, time and time again. Whereas, a stretch wrap machine consistently wraps pallets in the same way each and every time producing a clean professional finished product. Thus, if you’re looking for your pallet loads to project a professional image, it’s best to consider a stretch wrap machine

Eliminating any one of these justifies purchasing a stretch wrap machine. Let Best Packaging speak with you about a possible purchase and help you decide the right stretch wrap machine for your application by calling us at (888) 930 BEST.

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September 19, 2016 | Containment Force - Reducing Damage - Stretch Wrap - Stretch Wrap Machine - Stretch Wrappers - Stretch Wrapping | No Comment

Increase Your Stretch Wrap Success

When it comes to shipping, the main goal is to get products to your customer in good condition. One of the most practical means of achieving this is with stretch wrapping. Unfortunately, estimates show that nearly billions dollars of goods are lost each year due to poor stretch wrapping practices and constant jarring and vibrating of shipments in transportation.

There are many characteristics that influence the effectiveness of stretch wrapping such as the containment force, prestretch levels, film gauge, film width, the number of revolutions, etc. The best way to reduce much of the unnecessary damage is by managing these variables and making the adjustments necessary on the machine to ensure that your settings are aligned. However, here are a few simple things you can do to improve your chances of success:

Make sure your load has the proper containment force. Loads that don’t have enough containment force won’t be able to endure sharp turns and bumps during transit. To ensure you have the right containment force, double check the amount you’re currently using. Measure your loads with a tool designed to record holding force. If you need help finding the optimal amount of containment force, don’t hesitate to call Best Packaging Inc.
Secure your load on to the pallet, to avoid it slipping off. Stretch wrap is also designed to bind together the pallet and the load. The bumps and jostles of shipping can cause loads to come loose and without a tight seal around the load, it could get rattled or vibrated quite easily. Thus, a good stretch wrap ensures that wrap is tightly wound around the load and pallet. This creates a secure pallet and also facilitates the process of being quickly moved and stored. Loads should also be locked to the load with a film cable. Look for stretch wrappers that form a tight film cable. The film cable could mean the difference between having a secure load, or jeopardizing the film’s durability.
Double check for film tails. If a tail end of stretch wrap drags or dangles from the pallet, it could catch and tumble the entire load. It can cause serious risk to those who work around it. Invest in a stretch wrapper that features a film blower specifically designed to contain all loose ends and eliminate film tails. Guarantee there are no long film tails, as this could eventually unravel during the multiple times it’s handled during transport.

By paying attention to these details, you’ll be giving your loads the best chance to survive transportation damage. To learn more about reducing damage, give us a call at (888) 930 BEST.

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September 7, 2016 | Case Erectors - Casing Equipment - Conveyors - Emergency Service - Equipment Repair - Film Clamps - Packaging Equipment - Packaging Equipment Repair - Packaging Parts - Strapping Machine - Stretch Wrap Machine - Stretch Wrappers - Stretch Wrapping | No Comment

If You Can Wrap It, We Can Fix It

Picture this … It’s 3rd shift and your line goes down. Time is of the essence and to leave it until the morning could impact the bottom line and important shipments. That is where our 20+ years of combined experience and training on all brands and types of machinery can come to the rescue.

When a packaging line becomes faulty or fails, Best Packaging understands the urgency in fixing the problem immediately. That is why we are available 24 hours a day, seven days a week for emergency service. While some manufacturers recommend solutions that match their own personal business model, we recognize the BEST solution that fits each customer unique repair needs. If you find yourself in situation where you need one of your packaging machine parts repaired, you can count on our certified technicians to offer you on-site service or step by step instructions so that your staff can safely operate the machine. It is also highly recommended that you keep spare equipment parts on hand just in case. Therefore, Best Packaging works with trusted, reliable packaging equipment manufacturers to access the right parts for you. These are just a few examples of Best Packaging going above and beyond to save our clients time and money.

At Best Packaging, we make it a priority assist you with anything from installation to performance optimization. We offer spare packaging equipment parts and customized maintenance plans that will keep your equipment functioning at top performance levels. For more information on how Best Packaging can help with your packaging equipment repair needs, contact us at (888) 930 BEST

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August 15, 2016 | Shrink Wrap - Stretch Wrap - Stretch Wrappers | No Comment

Shrink vs. Stretch Wrap

The terms shrink wrap and stretch wrap are often used interchangeably, but the reality is, they are two different products. While they are both used for packaging purposes and are both clear plastic films, they serve different purposes during application. Understanding these differences can save you the frustration of ordering the wrong film.

Stretch wrap is an elastic film commonly used to wrap and secure loads on pallets for shipping purposes. As the products are wrapped in the film, tension is applied as it is wrapping several times around the load. The properties of the wrap cause it to cling to itself creating a tightly wrapped, secure packaging. Stretch wrap can come in a variety of specialty films such as: UV stretch film, colored stretch film, prestretched stretch film, etc., making it more adaptable than other films.

Unlike stretch wrap, shrink wrap is a clear plastic film that is not stretchy. Shrink wrap covers loosely around a product and shrinks tightly when heat is applied. It is typically used to professionally package retail items giving them a tamper proof and protective barrier. Shrink wrap is mostly used to wrap individual items such as CDs or meats, but can still be used to package multiple items together. Shrink Wrap has the option of being ventilated, which creates an advantage in reducing any damage that can occur from moisture.

Whether your application calls for stretch film, shrink film, or both, let Best Packaging help you find the right materials and equipment for you. Give us a call at (888) 930 BEST to set up a consultation.

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August 8, 2016 | Case Erectors - Casing Equipment - Packaging Equipment - Preventative Maintenance - Reducing Cost - Strapping Machine - Stretch Wrappers | 1 Comment

If It’s Not Broken, Keep It That Way

The term ‘If it’s not broken, don’t fix it’ still applies to many industries. However, with preventative maintenance that phrase becomes “If it’s not broken, keep it that way.”

With packaging equipment, there are many common problems that can arise. Therefore, it’s important to establish a proper preventative maintenance program. The purpose of a preventative maintenance program is to provide long term maintenance and quality care in order to avoid any unplanned problems that might arise.

Simple preventive maintenance not only extends the life of your packaging equipment, it keeps money in your pocket for the days ahead. Companies that don’t participate in a preventative maintenance program are essentially waiting for a problem to happen, and this is often a very costly move. A case study performed by The Association for Packaging and Processing Technologies shows that PM generates a solid rate of return in terms of risk mitigation and asset protection (Koo 4). In other words, an investment in PM not only pays for itself, but it also produces a huge return on the investment. With PM, efforts are focused on preventing equipment failure rather than responding to emergencies, which has proven to be much cheaper and faster than big repairs.

Without a proper protocol to keep your packaging equipment in good condition , it can be very challenging to run a stable, consistent business. An unexpected failure can result in idle employees, halting the production line, missed deadlines, and long-term damage to their brand. With PM, however, companies are able to recognize problems earlier thereby eliminating the chance of machine breakdowns.

Best Packaging understands the financial impact of a packaging line not running properly or not running at all. Our trained service technicians can assist with your ongoing maintenance requirements to keep your packaging equipment healthy and running at maximum efficiency. We also offer thorough training to make sure your operators are confident running the equipment.

Don’t wait until the entire machine goes down and money is lost while it is out of commission. Prevent major catastrophes by stopping the problem before it starts. Call Best Packaging at (888) 930 BEST or click here to schedule a PM today.

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August 1, 2016 | Containment Force - Reducing Cost - Stretch Film - Stretch Wrap Machine - Stretch Wrappers | No Comment

May The Containment Force Be With You

In order for loads to be wrapped correctly for shipping, you must apply the right amount of containment force. Containment force is the number of film revolutions multiplied by the wrap force. There is a right amount of containment force for each load that ensures that the load is stable and held firmly enough. There are a few things you could do to detect the optimal amount of containment force using the least amount of film. For example, you can experiment with different types of stretch film, alter the machine gauges and prestretch levels, or manipulate the wrap force settings. However, the best way to find the ideal containment force is to test the top, middle, and bottom of the load with a containment force tool.

At Best Packaging, we have the testing technology required to measure and determine the proper containment standard in order to make sure your film can maintain a particular load holding force over time.Using our portable film force system, we can help you identify the minimum containment force required to decrease film costs.

You shouldn’t be alarmed if your containment force isn’t distributed evenly throughout your load. In fact, the lowest containment force value recorded should become your target for shipping a stable load. For instance, if you’re measuring various pounds of containment force at the top, middle, and bottom, but you’re shipping without any issues, it’s best to set your containment force at the at the lowest-mid containment standard. Doing so ensures you must have at least the minimum amount of containment force everywhere on the load in order for it to be safe to ship. By understanding the different distribution channels, Best Packaging is able to give recommendations on the appropriate settings when sending out different loads.

Once you’ve learned how to measure and have achieved the right containment force, you’ll be able to enjoy consistently safe loads, and more importantly, consistently happy customers. To learn more about containment force or how we can help you measure it, call us at (888) 930 BEST

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July 25, 2016 | Reducing Cost - Stretch Film - Stretch Wrap | No Comment

Stretch Film 101

Many consumers don’t realize that stretch film plays an important role in delivering and transporting many of the products they use. Stretch Film is the highly elastic plastic material used to wrap products and secure them onto pallets. It is most commonly used to unitize products for efficient storage, but also serves as protection for transportation.

Stretch film is made from LLDPE (Linear-Low-Density Polyethylene). LLDPE is the ideal material for wrapping and securing loads because of its flexibility. The film’s ability to stretch around corners of products, boxes, and pallets offers increased puncture and tear resistance as well as greater efficiency when applied appropriately. High puncture and tear resistance guarantees that the load will remain stable and secure during transportation. Increased puncture resistance as well as a reduction of cost can be detected when the film reaches its maximum stretch potential.

At Best Packaging, we use state of the art testing technology to evaluate stretch film performance. If you’re currently wrapping products with stretch film and want to ensure you’re getting the maximum stretch potential, give us a call at (888) 930 BEST. By helping you understand your wrapping operations better, we can recommend solutions to reduce costs and improve your wrapping performance.

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July 18, 2016 | Stretch Film - Stretch Wrap - Stretch Wrap Machine - Stretch Wrappers - Stretch Wrapping | 1 Comment

Understanding The Purpose And Methods Of Stretch Wrapping

One of the main uses of stretch wrap is to consolidate many smaller individual packages into one larger unit. Reshaping the load into one solid unit makes it easier to transport. By only having to transport one unit, this saves distributors time and damage when loading.

Quality and Appearance are also important. We want our customers deliver to be able to ship their product(s) in good condition- which is why we stretch wrap. Stretch wrapping allows us to unitize our loads and protect the product from damage which contributes to lower admin costs and happier customers.

As a result, stretch wrapping is now the preferred method for unitized shipping of goods. Most companies that utilize production warehouses are most likely familiar with stretch wrapping. However, in order to make the right decisions about stretch wrap machines, it’s important to be properly informed. There are three methods of stretch wrap application: manual, semi-automatic machine, and high speed automatic machine.

A manual wrap requires workers to wrap a load by hand. This involves attaching the film to the pallet and then using a roll of stretch wrap on a bar to wrap the film. Workers start at the base and then walk around the load to make certain that the entire pallet is wrapped thoroughly. The amount of manual labor involved with stretch wrapping a pallet by hand is high and often takes a lot of energy. Therefore, this method is ideal for small operations where only one or two pallets a day require wrapping.

Semi-automatic stretch wrappers have the machine perform the actual stretch wrapping. On semi-automatic stretch wrappers, the pallet is placed on a turntable rotating the pallet as the film moves up and down. Semi-Automatic Stretch Wrap Machines are more ideal for larger shipping and manufacturing industries that wrap about 100 pallets per day and are designed for use with a forklift or a pallet jack. There are also features that could be added to the semi-automatic machines that can increase automation.

High speed automated stretch wrappers usually incorporate conveyors to automatically cycle loads through the machine for increased output and efficiency. These stretch wrappers can keep up with the most demanding production rates. Automatic stretch wrappers apply and cut the film, so the only thing you need to do is change the film roll. Since the load remains stationary, they are ideal for wrapping very light, very heavy, tall or unstable loads.

Best Packaging offers a variety of stretch wrappers at affordable prices. For machine wrapping solutions, call us at (888) 930 BEST

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July 11, 2016 | Reducing Cost - Stretch Wrap Machine - Work Injuries | No Comment

How To Reduce The Cost Of Work Injuries

As an employer, it’s your responsibility for taking care of the health and safety of your employees. A serious work injury can change someone’s life and the lives around them forever. A work-related injury can also negatively affect the company by increasing costs to your business. Therefore, it’s important to take necessary measures to maintain a healthy and safety work environment.

If workers are injured on the job, it costs the company in increased insurance rates, workers’ compensation premiums, lost work hours, and possible litigation. If an employee sues because of a work-related injury, a company could run into some serious financial trouble; whereas keeping employees healthy helps companies keep the cost of insurance premiums down. Work injuries can also decrease worker productivity if other workers get distracted or the injured worker needs to time off to heal. Thus, reducing the amount of injuries allows employees to keep the focus on the quality of what they do.

In the packaging industry, one of the most common injuries comes with operating a forklift. Employees often have to maneuver in and out of forklifts which can lead to pain in their backs, knees, etc. However, there is an alternative that can help reduce the risk of those injuries. Obtaining stretch wrappers with an automatic cut and clamp saves the operator the hassle of getting in and out of the forklift as often, which can minimize the chance of injury or falls. Therefore, having the stretch wrapper that automatically attaches and cuts film during the wrap cycle can potentially reduce the risk of injuries and save the company thousands.

Another common injury involves hand wrapping a pallet. Depending on the size and structure of the pallet that you are wrapping, there is a large amount of bending and twisting involved in making sure that the entire pallet is wrapped thoroughly. Even with orderly and square pallets, hand wrapping requires that an employee walk around in circles which can cause dizziness. The amount of physical work involved with stretch wrapping a pallet by hand often takes a lot of energy that employees will need throughout the day. Upgrading to a stretch wrapping machine can greatly reduce the amount of labor required to wrap a pallet which will ultimately retain the health, energy, and safety of your employees.

Reduce the cost of work-related injuries by calling Best Packaging for a consultation to introduce a stretch wrapper into your manufacturing process today. (888) 930 BEST

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April 10, 2016 | Stretch Film | No Comment

Is Your Stretch Film Living Up To Its FULL Potential?

Here at Best Packaging, we see this all the time. If a stretch wrapper is not actually “stretching” the film to its full potential, you are throwing money out the window. In addition, increasing the stretch of the film will increase the containment force. A load wrapped with a machine which is not stretching the film properly is much more prone to shipping damage. Many companies don’t take these factors into account. They think that as long as their machines are working, they are working properly.

We recently got a call from a customer who has large distribution centers in many states and is wrapping 2500 pallets per day. Their corporate office had noticed a trend that a distribution center in one state was spending much more in film costs per year than their other locations, even though they all used the same machines and the same film. These machines are meant to stretch the film at 250%. When the Best Packaging team arrived we quickly found that some of their machines were working properly, stretching the film to 250%, while others were stretching the film significantly less due to mechanical failures in the film carriage. Using state of the art testing technology we were able to determine that these faulty machines were costing this customer about $600 per day in added film cost. We quickly worked to resolve the issues with the film carriage and this location is now exceeding their film cost benchmark.

If you don’t know how much your machines are stretching the film or how much you are paying per load, give us a call. We can perform a machine audit and provide a report on your machine performance, film cost, and recommend solutions to bring your costs down. A small investment in testing could save you a lot!

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