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Extremus stretch Film


How a bedding manufacturer saved thousands of pounds 

and reduced their plastic waste by swtiching to Extremus


The background

A family-run bedding manufacturer with a large presence in the UK and Europe invited Hazel 4D to review the problems they were having with their pallet wrapping machines and stretch wrap.

We have worked with this rapidly expanding company for many years supplying various other packaging products. They produce tens of millions of pillows and duvets annually and ship an estimated 195,000 pallets per year.

The challenge

The company’s pallet wrap machine operators had lost confidence in the stretch wrap they were using. It was continually breaking and snapping which was causing downtime. Operators were loading the film onto the machines incorrectly in order to prevent breakages. Damage on the outside of the rolls meant lots of film was being wasted at the beginning of a roll. Significant amounts of film were also wasted as pallets were being wrapped several times to ensure the full wrapping cycle was completed.

Our approach 

Hazel 4D visited the company’s manufacturing facility and warehouse to assess the situation and talk to operators about the problems they were experiencing. We ran tests on each of their 10 pallet wrapping machines using their existing stretch film. We calculated the weight of film used, the number of revolutions needed to wrap a pallet, calculated the pre-stretch of the film and made general observations about the process.


Our tests revealed huge variances in the pre-stretch of the film, the film overlap and weight of film applied per pallet. The film was incorrectly loaded on 3 of the machines and there was evidence of slippage. The pallet wrap machines were in need of service or repair and the film tension controls were damaged on several machines.

The solution 

Hazel 4D worked with the operations team at the company to achieve the maximum possible savings in terms of applied film cost, waste elimination, efficiencies and damage reduction. 

We replaced 3 of the company’s machines with Robopac pallet wrapping machines and swapped their stretch wrap for our Extremus Stretch Film, a high-performance load holding film with a high tear resistance. We spent time training their operators on the science behind stretch wrapping, how to load the Extremus Film correctly and its benefits for load stability.

Working with their in-house engineers, we optimised the settings of the wrapping machines to increase their performance and save time and money. 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.

The outcome  

As a result of the changes, the company saved £93,900 on their annual pallet wrap spend. 

By switching their stretch wrap to Extremus, less film was required to wrap each load, the weight of film used to wrap a pallet decreased and the cumulative average pre-stretch of the film increased by 214%.

Production downtime was reduced as the strength of the Extremus Film prevented film slippages and breakages and reduced the need for roll changeovers. Damage at the beginning of rolls was eliminated so film wastage was reduced. 

Using Extremus Film and optimising the settings of the machines increased the rigidity of the pallets, reduced damages in transit and allowed the company to bulk stack pallets safely. 

The operators could now load the film correctly and pallet wrapping practices across the company were improved. 

We will be conducting frequent audits to check that savings and operational improvements are being maintained.

The Purchasing Manager at the company was extremely pleased with the improvements made and is recommending Hazel 4D and Extremus Stretch Film to other businesses:


“As discussed, please find the contact details for the stretch wrap supplier who recently did a project for us and saved 2/3 of our requirement and approx. £100k!
With Hazel 4D’s input and knowledge, they have put best practice into the production area which we continue to monitor.”



Summary of benefits achieved

  •  Annual stretch wrap spend reduced by £93,900

  •  Production downtime reduced

  •  Less film needed to wrap each pallet

  •  Reduced plastic film consumption from 84 tonnes to 36 tonnes

  •  Operators can now load film correctly

  •  Increased cumulative average pre-stretch of film

  •  Reduced need for roll changeovers

  •  Damage at beginning of film roll eliminated

  •  No film slippage or breakage

  •  Improved rigidity of pallets

  •  Reduced damages in transit

  •  Pallets can now be bulk stacked safely

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