Many manufacturers in 2021 saw increased demand, supply chain shortages, labor shortages, and let’s not forget the ever-present threat Coronavirus had on keeping your doors open. Whether you’ve jumped one or all of these hurdles, one thing is for sure… 2021 has left us all saying, ‘oh brother, what’s next!?’ 2022 as yet remains shrouded in mystery, so to quell your anticipatory anxiety, here are two DO’s and two DON’Ts that the experts at Best Packaging recommend to help you ‘baton the hatches’ to your end of line and prepare for whatever comes next.
Don’t
Fall behind on Preventative Maintenance
When you’re constantly adapting to new circumstances, everyday maintenance tends to fall by the wayside. But that’s precisely when it is needed most! Failure to regularly clean, lube and exchange worn parts can escalate a minor breakdown to a total catastrophe. Consider boosting your PM plan with performance monitoring technology. By combining line counter data with hands-on technician experience, you’ll get the clearest insight to predict wear and tear issues.
Overspend on Disposables
Disposables like stretch film, tape, and corrugate are called such because they are intended to be used once and thrown away. When you spend more than you need on single-use materials, you are essentially just throwing your money away! This happens when case tapers require more than one pass, when stretch film is so thin that it requires additional wraps, or when your cases are thicker than necessary for your application. Getting the right thickness or tension is a delicate science best left to an expert. Find out where you could be saving money by having our team of production line designers (and an ASTM contributor!) audit your plant for inefficiencies.
Do
Explore Automation
Integration doesn’t JUST mean robots. Advancements in manufacturing technology have steadily been picking up steam over the past few years. The infrastructure is finally available to make Industry 4.0 technology not only feasible for the average manufacturer, but affordable too. Take a few baby steps into the vast realm of IIOT (Industrial Internet Of Things) by implementing sensor automation with PLC integration to your existing equipment.
Take Care of Your Team
At a time when labor is scarce and employee welfare is ever the subject of public scrutiny, consider what you could be doing to improve plant safety or reduce the strain on your machine operators and material handlers. For example, graduating to a semi-automatic packing system, like a Wexxar Bel 507 & 150 combo that features a tilted packing station for better ergonomics could increase your packages per minute and still keep your valued workforce comfortable while performing repetitive motions.
If you are interested in exploring any of the solutions we suggested above, we’d love to get in touch! Or, if you need something more specific, Best Packaging is happy to assess your current production line to create a more personalized recommendation for improvements to your system. Contact us for more info!
Using a generous amount of shrink-wrapping film might seem harmless or even the right thing to do. Better to overestimate, than underestimate when it comes to sizing, right? Wrong! Over time, you may experience shrinking profits as your materials costs increase. In fact, it’s better to simply get it right the first time.
Nailing down your shrink film measurements is easier than you might think. Finding the proper film width and length will depend on what type of film you are using. You will need to know a few facts and measurements before calculating your shrink film dimensions. In this article, all measurements are in inches.
- Orientation/flow through shrink tunnel (This will inform which side is your product length vs your width)
- Type of machine (this will dictate what type of film you need)
- Production/Conveyor Speed
- Product dimensions (always round up to the nearest inch)
- Width: parallel to the cut-off or cross seal
- Length: parallel to the fold of the film, in cases of centerfold film
- Height: In cases of products with uneven surfaces, the height should be considered from the bottom to the highest point of the package
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The most common forms of shrink wrap film are tubing, centerfold film, and shrink wrap bags. Conveniently, there is a formula to calculate the proper measurements for each kind.
Centerfold: Combine the height and the width of the item, then add 2-3 inches of wiggle room. (3 for larger items only). The formula for this is H+W+2.
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Tubing: Tubular shrink film is typically only used for oblong objects. To determine the width of your shrink film tube, multiply the circumference of your object by 1.15, then divide your total by 2. In other words, (CIR×1.15)÷2. As for the length of your shrink wrap tube, simply add 2-3 inches to the length of the object.
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Shrink Bag: For most applications, bags are the most beginner-friendly solution to shrink wrapping. They are already sealed on 3 of the 4 sides, which makes packaging your item simpler. To find the right width for your shrink bag, follow this formula: (CIR×1.13)÷2. As with our previous examples, the length of your shrink bag should be the length of your object, plus 2-3 inches.
Every application is different and finding the right size film can be even more difficult when your item is an irregular shape. When in doubt, ask an expert. Every service technician at Best Packaging is trained in shrink wrapping procedure. During your next visit, ask a technician to take a look at your shrink wrapping line and your product to get a shrink film recommendation.
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With so many manufacturers misusing stretch wrap vocabulary, it can often be difficult to understand the true meaning of these terms. To help consumers understand the real meaning, we listed a few of the most commonly misused terms in the packaging industry. In doing so, we hope to educate consumers so as to not be fooled by deceptive terminology when evaluating stretch wrap options.
Pre-stretch is the process of elongated film to a percentage of its original length. The advantage of operating with pre-stretch is that it provides great load stability and allows you consume less film per pallet. Below are two different methods to obtain pre-stretch.
- Pre-stretched stretch film is film that is stretched during the manufacturing process prior to being wound up in rolls for stretch film application. The majority of pre-stretched stretch film is applied using hand wrap dispensers.
- Another means of obtaining pre-stretch film is by elongated it using the motorized pre-stretch capabilities of a wrapper. The film passes through two film carriage rollers running at different speeds that stretch the film prior to being applied to the load.
A common misconception within the packaging industry is that stretching the film activates its elastic memory, triggering the film to return to its original state. Another mistake is assuming the two methods of obtaining pre-stretch produce the same outcome- although that’s not necessarily the case.
Suppose you have a roll of pre-stretched stretch film at $5 per roll that gives you 15ft of surface area to work with and 15ft of regular stretch film at $8 per roll. Naturally, the $5 already pre-stretched film would appeal to most plant managers. However, when operating under the correct settings, there could be more to gain from producing pre-stretched film using a stretch wrapper.
If your stretch wrapper is operating at 250% stretch, the regular stretch film at $8 per roll could potentially give you 25ft, as opposed to the pre-stretched film coming in at 15ft. Despite the regular stretch film coming in at a higher cost, it’s winds up more valuable because you’re getting more use of that film while consuming less. By choosing to stretch your film using a powered stretch wrapper, you save money on film and overall lower operating costs.
Force-to-Load is a measure of how tight the film is being pulled as it exits the carriage and is applied to the load. Force to load plays a key factor in maintaining a percentage of prestretch. Although force-to-load does not hold your pallet, the amount applied does contribute to all around containment force.
Containment force is the amount of load retention created due to the film’s stiff properties. Containment force is the property that holds your pallet together during transit. Typically, for every 100lbs of product, you want to have at least 1 lb of containment force. Containment force and pre-stretch ought to be assessed on a regular basis to ensure the stretch wrap is being applied accurately. To evaluate the performance of your stretch film and application process, there are several testing methods that can be employed. These methods include using a film force pull plate, pull bar, double finger, or even replicating the delivery of a pallet via freight truck with a vibrations or tilt test.
Understanding this terminology can make a difference in terms of stretch film cost savings, ensuring that your load is held tightly enough, and avoiding film breaks that could potentially damage your product. Instead of buying more or new film, you may be able to simply adjust your stretch levels. Knowledge of these terms and how to correctly use them enables consumers to make more informed decisions when comparing options for your packaging line. For more information, contact us at 888 930 BEST.
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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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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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