Our customer, a long-established international childcare products brand, was using dated machinery and failing to get the best out of its stretch film. Our initial project with them has reduced stretch film usage by 75% and made very significant savings.
When we tested their pallet-wrapping we found a blend of problems leading to significant plastic waste, unnecessary cost, inefficiency and instability, and in turn, to damaged returns from major retailers. Wrapping a range of differently shaped packages using a turntable was creating unstable loads, which were prone to tearing.
To try and counter instability they had switched to a thick 30 micron stretch film, adding weight to the pallets, increasing costs and waste without solving the problem – it was also inefficient because operatives had to manually assist the machine process.
After conducting a thorough audit we worked closely with our customer to develop a new system tailored specifically to their needs. We replaced the old pallet wrapper with a new high-performance PPS pallet wrapping machine with lockable programmes. We even created multiple bespoke pre-programmed settings on their new machine to respond perfectly to their needs.
The machine was installed free of charge on a pay per-wrap system. We also replaced their 30 micron stretch wrap for our 15 micron Extremus stretch nano film, a high-performance load holding film with a high tear resistance. Using our state-of-the-art mobile testing system, we measured the forces exerted on wrapped pallets to fix instabilities and improve the rigidity of the pallets.
“I had no idea we were applying over 1Kg of film per pallet. Hazel 4D have successfully achieved a much safer pallet with less than a quarter of the film weight.”
Distribution Centre Manager
51%
annual cost saving
75
Plastic reduction
£1
cost reduction per pallet wrapped
287%
Increase in average pre-stretch of film
