How our Intelligent Load Stability system saved one customer £100,000 a year

A food manufacturer was incurring excessive financial and operational costs due to ineffective stretch wrapping processes.

The company was spending around £150,000 annually on stretch film, using 100 tonnes of plastic film and spending time and money repairing old machines.

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The Problem

Worn, damaged wrapping machines were causing stretch film to break and meant wrapped pallets were extremely unstable. The machines were unable to keep up with production during peak periods which resulted in bottlenecks and downtime.

Large supermarket chains were rejecting and returning damaged and leaning shipments, so warehouse operatives were spending a significant amount of time re-wrapping pallets. The frustrated operatives were loading the stretch film incorrectly in an attempt to prevent film breakages and keep the machines wrapping. Their Warehouse Manager repeatedly commented ‘my guys deserve better’. The problem was costing them money, time and their reputation.

Our Solution

We recommended making the switch to Extremus film and new state of the art turntable pallet wrappers, which when optimised could deliver up to 300% stretch. We created two bespoke wrapping programmes to suit their needs, whilst using the minimum volume of stretch film. Due to the combination of film and equipment used, the ROI on the new machines was less than 7 months.

Careful training and ongoing contact as part of the maintenance contract with the team at Hazel 4D meant that the operations team was confident in using the system, and that savings were realised on an ongoing basis and the team could call Hazel 4D with any issues.

Project outcomes

  • Huge cost savings in excess of £100,000 a year
  • Reduced plastic waste impact by 65%
  • Production downtime reduced
  • Improved stability of pallets

  • No film breakages
  • Increased number of pallets wrapped per day
  • Reduced need for roll changeovers
Not a single pallet has been returned from our customers. Why didn't we do this years ago?

Distribution Manager - Food Manufacturer

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Environmental impact

Introducing sustainable alternatives that don’t break the bank

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Leading edge technologies

We use a global network of partners to bring you the latest packaging innovations at competitive prices

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Our Team

Our team of experts includes technical consultants, packaging technologists, project managers and procurement specialists. Many of them have been with Hazel 4D for over 20 years.

To see their smiling faces, visit our meet the team page or get in touch to arrange a site visit.

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Case Studies