For many end-of-line packaging professionals, the choice of pallet packaging method may not immediately surface as a critical success factor when designing, upgrading or refurbishing a production line or distribution center. There are many aspects that should be considered when choosing a pallet packaging method, as the choice can significantly impact overall profitability and distribution chain performance.
There are three recognized methods available for pallet packaging: conventional spiral stretch-wrapping, heat shrink-hooding, and stretch-hooding. Each method has its advantages and disadvantages depending on the specific application. In the final part of the series we will examine stretch-hooding. You can read parts one and two, if you missed them.
Stretch-hooding
Introduced in the late s, the stretch-hooding method of pallet packaging has, over the past decade, gained significant market share at the expense of heat shrink-hooding and spiral stretch-wrapping -- not only for bagged products, but also for products in Octabins, cases, pails, and other similar primary packaging formats. The primary reason for this is that stretch-hooding provides superior value with respect to operating costs, speed, reliability, and distribution chain performance.
The quality of today&#;s domestically-available, co-extruded stretch-hood films allows for pre-stretch percentages exceeding 80 percent, providing better film yields than what was possible even a few years ago. This performance, combined with film thickness reduction down to 1.6 mils, means that the per-pallet film cost with stretch-hooding is extremely competitive with that of spiral stretch-wrapping. And the stretch-hood equipment can be programmed to allow for application-specific selection of a non-sealed sleeve (for lowest possible film consumption), a closed hood (for optimal protection and stability), or even an open hood (to avoid moisture condensation for food packaging).
The hood is formed from gusseted tubing, and the height of the pallet load is measured automatically as the pallet enters the machine -- ensuring that only the amount of film required for the application is precisely dispensed. Among other operating benefits, energy consumption is very low since the film is not heated, and available servo drive technology further reduces energy and maintenance costs.
The high quality of today's films means that a single film hood format can, within certain limitations, be used to stretch-hood multiple pallet sizes. However, it is important to analyze the net financial benefit of a one-size-fits-all approach, as the total film cost will be lower if each pallet size has a dedicated film hood format.
Unlike spiral stretch-wrapping, stretch-hooding provides ready evidence of tampering, as it is not possible to remove a product from the pallet without tearing the film. The smooth film surface also provides for easier loading and unloading of trailers. With spiral stretch-wrapping, the friction between the films on two pallet loads can cause tears and film tails to come undone, compromising the integrity of the pallet load.
For products sold at retail outlets, such as home centers, the clear, one-layer, stretch-hood film provides much better product recognition at point-of-sale than multi-layer spiral stretch-wrap film does. It is also possible to print advertising or handling instructions on the stretch-hood film. And stretch-hood film allows for easy bar-code scanning, virtually eliminating misreads and associated remedial costs.
Consistently maintaining its tension, stretch-hood film is particularly well-suited to products that, due to their physical properties, tend to settle after being bagged and palletized.
Recent advancements in stretch-hood technology have reduced film cost per-pallet-load, while simultaneously offering more intuitive user interfaces, reduced energy consumption, smaller machine footprints, and throughputs exceeding 150 pallet-loads-per-hour. Modular designs also allow for faster, and less costly, installation. In addition, the use of intuitive graphic user interface screens helps with ease of operation and troubleshooting. For example, BEUMER has implemented features that allow the machine operator to switch between different international languages with the touch of an onscreen flag icon. Furthermore, the operator can select metric or U.S. units.
Cost of ownership
Properly evaluating the choice of pallet packaging method goes far beyond comparing equipment acquisition costs. Several factors can significantly impact the cost of ownership and, consequently, the return on investment.
Equipment cost. Spiral stretch-wrapping equipment is available in multiple speed ranges and varying degrees of automation. With prices ranging from below $10,000 for semi-automatic low-speed models to $120,000+ for high-speed rotary-arm or satellite models, there is generally a spiral stretch-wrapping model for every budget.
Heat shrink-hooding equipment also comes in both semi- and fully automatic models. The price range is generally between $50,000 for semi-automatic models (where the operator applies a pre-made shrink bag over the pallet load) and $200,000+ for fully automatic, high-speed models.
The price of stretch-hooding equipment has come down somewhat over the past couple of years due to increased competition and the development of simpler equipment. Prices range from roughly $140,000 for single-format equipment to $200,000+ for multi-format equipment. For high-output facilities, it is important to realize that one single stretch-hood machine can replace multiple spiral stretch-wrap machines due to the higher achievable speeds.
Film cost. If protection and stability are secondary, the film cost for spiral stretch-wrapping a pallet load can be very low because of minimal film thickness and comparatively high pre-stretch percentage. Where protection and stability are critical, however, multiple layers of stretch-wrap film must be applied for stability, and a top-sheet added for protection. This can greatly increase film cost per pallet.
Heat shrink-hooding is significantly more expensive in film cost per pallet than either of the other two methods because of the need to oversize the film hood prior to shrinking. The film cost per pallet for shrink-hooding can easily exceed that of stretch-hooding by 40 percent or more. And substantial energy costs associated with heat shrink-hooding add to the cost-disadvantage of this method.
For stretch-hood film, recent developments have enabled the use of much thinner films with significantly higher pre-stretch percentages than was previously possible. This makes stretch-hooding competitive with spiral stretch-wrapping in terms of film cost per pallet load for applications where moderate load stability and protection is required.
Labor and maintenance cost. Spiral stretch-wrapping equipment is simple to operate and maintain. Semi-automatic models, in particular, require little training for operation. Maintenance costs, however, tend to the high side because of the quantity of moving components. The drawback of spiral stretch-wrap equipment is that the relatively low-volume film rolls require frequent replacement at higher throughputs. Some manufacturers do offer an automatic film change option; however, this cancan be an expensive option, adding complexity to the equipment. Having to replace the film roll at short intervals reduces line availability and increases direct labor costs. The resulting costs from outdoor storage, or measures to protect from the weather, can be significant and must be included in a total cost-of-ownership analysis. Heat shrink-hooding equipment is moderately maintenance-intensive in comparison with spiral stretch-wrapping and stretch-hooding, as heat shrink-hooding involves more wear parts that require replacement at regular intervals.
The least labor-intensive method of pallet packaging is stretch-hooding. The film roll can be up to 39-inches in diameter, easily allowing for 10 times longer film change intervals and increasing line availability. Troll change is a very simple procedure typically taking no more than 10 minutes to return the machine to production. Unlike stretch-wrapping, adjustments to machine settings are rarely necessary, thus ensuring consistent high-quality packaging results. Moreover, with fewer wear parts than stretch-wrap machines, stretch-hooding equipment requires very little maintenance, and five-sided protection eliminates the need for tarping.
Making the choice
Making the right choice of pallet packaging method involves a thorough analysis of many factors that influence not only the daily operating costs, but also the entire distribution chain performance. When product leaves the production facility, it is at its highest value-added state and should arrive at the customer&#;s facility in the same condition.
For low-throughput applications, where stability and protection are secondary to initial acquisition cost, spiral stretch-wrapping still provides an attractive alternative. However, if production line efficiency, protection against the elements, superior stability, and product recognition at point-of-sale are important criteria, then stretch-hooding is the preferred solution as it offers the best combination of packaging performance and total value of ownership.
In industrial packaging, the choice of film can significantly impact the effectiveness of palletized loads. The packaging industry offers a variety of films, each with its own application, advantages, and unique properties. In this article, we will explore the characteristics of three of the most commonly used films: Stretch Film, Shrink Wrap, and Stretch Hood.
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Stretch Film
Stretch film is a versatile pallet packaging solution utilized by Stretch Wrapping machines, both semi-automatic and automatic. The film stretches and wraps around the load, providing stability during transport.
Advantages of Stretch Film
1. Versatilibility
One of stretch film&#;s primary strengths lies in its versatility, with various subtypes designed to cater to specific packaging requirements. Stretch Film offers unparalleled versatility, catering to various needs such as standard stretch film, pre-stretched film for easy application, and micro-perforated film that enhances ventilation for palletized loads.
2. Load Support
A key advantage of Stretch Film is its remarkable load support capabilities, particularly when applied using automatic wrapping systems. The film generates tension during the wrapping process, allowing for high levels of stretch, ranging between 25% and 300%.
Films applied through automatic wrapping systems can achieve even higher stretch levels, reaching between 150% and 300%, depending on configuration. This unique feature ensures a tight and secure wrap, enhancing stability during transit.
3. Variability
The variability of Stretch Film allows for different tension levels. This adaptability makes it suitable for a wide array of industries, from food to manufacturing and logistics. In both semi-automatic and automatic stretch wrapping machines, Stretch Film demonstrates its effectiveness in delivering load support, stability, and protection.
Shrink Wrap
Shrink film, as the name suggests, relies on heat shrinkage for securing the load. It is presented as a tubular film reel, and when heat is applied, it conforms to the load&#;s shape, offering comprehensive coverage.
Advantages of Shrink Wrap
1. Complete Coverage
Shrink film&#;s primary strength lies in providing complete coverage for the load, forming a tight and protective seal. The tubular film, when subjected to heat application, adheres to the load&#;s contours, offering a comprehensive shield against external agents. This feature makes Shrink Wrap particularly effective in environments where safeguarding the entire load from potential damage is important.
2. Compaction and Customization
Another noteworthy advantage of Shrink Wrap is its ability to achieve superior compaction and resistance compared to Stretch Film. The heat-shrinking process allows the film to tightly conform to the load, enhancing stability during transportation. Customization options, such as incorporating anti-UV and anti-static properties, further enhance its protective capabilities, making it suitable for a wide range of industries.
In specific sectors like construction, Shrink Wrap find provides protection for products such as tiles and bricks without the need for additional primary or secondary packaging. The heat-shrinking process ensures uniform adherence to loads of specific sizes and configurations, showcasing the adaptability of Shrink Wrap to specialized industry needs.
Stretch Hood
Stretch Hood film is a specialized packaging material designed for the Stretch Hood packaging system. This film is stretchable and adheres tightly to palletized loads, offering secure and efficient packaging by conforming to the shape of the items on the pallet. Stretch hood film brings forth a number of advantages, such as the following:
Advantages of Stretch Hood
1. Multilayer Composition
One key advantage of Stretch Hood film is its multilayer structure, offering tear strength, puncture strength, and holding strength. This unique composition includes external layers to enhance puncture resistance, additives for purposes like anti-UV and anti-condensation, and 1 or 2 layers of LLDPE to provide elasticity. An inner layer further ensures mechanical resistance and stretching, creating a comprehensive shield for the palletized load.
2. Cost-Efficient
Cost efficiency becomes a notable aspect of Stretch Hood&#;s advantages. Unlike Shrink Wrap, it doesn&#;t require a heat source for application, resulting in reduced energy costs. Additionally, its use of smaller and thinner film hoods contributes to savings in the amount of film used, making it an economically attractive option.
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3. Sustainable and Efficient
Unlike Shrink Wrap, Stretch Hood achieves load stability and protection without requiring additional thermal energy. This offers environmental and economic benefits. The absence of a heat requirement leads to significant cost savings by eliminating the energy-intensive process, making Stretch Hood an economically attractive and sustainable packaging option. This feature enhances efficiency while minimizing the ecological footprint associated with packaging operations, aligning with environmentally conscious practices.
Industry-Specific Applications
The selection of pallet films is not a one-size-fits-all decision, and understanding how each film type suits different industries is important for making informed choices.
Stretch Film
Best known for its versatility, Stretch Film is a reliable choice across various industries. In the food sector, it excels in securing and preserving perishable goods during transit. In manufacturing, Stretch Film plays an important role in stabilizing products, ensuring they reach their destination intact. Its adaptability extends to the logistics sector, where it provides the stability necessary for the safe transport of goods.
Shrink Wrap
Shrink Wrap, with its heat-activated precision, is tailored for specific industries with unique packaging requirements. This is especially true in construction-related sectors, where products like tiles and bricks need protection without additional primary or secondary packaging, Shrink Wrap is the first choice.
Its ability to conform uniformly to specific load sizes and configurations makes it an ideal choice in industries where load uniformity and heat-activated shielding are a must. In such specialized applications, Shrink Wrap provides the tailored protection necessary for the demands of the construction sector.
Stretch Hood
A relatively newer variant, Stretch Hood film is becoming popular, especially in industries with boxed or bagged products. Its application extends to sectors such as ceramics, paper, food, and cement, where it excels in providing total protection and a superior final packaging finish.
The adaptability of Stretch Hood to various load types, including both boxed and bagged products, positions it as a versatile choice across different sectors. The film&#;s multilayer composition, along with its tear, puncture, and holding strength, makes it particularly effective in industries where robust load protection is critical.
Sustainability and Environmental Impact
Amid growing environmental consciousness, it is important to evaluate the sustainability of packaging materials. Choosing sustainable films for your business can contribute to the overall goals of a greener world.
Stretch Film
The sustainability of Stretch Film is due to its diverse range of options catering to different environmental concerns. Pre-stretched films and perforated films are alternatives that enhance sustainability. Pre-stretched films reduce overall material consumption, promoting resource efficiency. Meanwhile, perforated films not only offer ventilation for palletized loads but also contribute to minimizing environmental impact.
In fact, Stretch Film is an environmentally conscious choice, providing versatility without compromising on eco-friendly practices.
Shrink Wrap
Shrink Wrap is known for its energy-intensive heat-shrinking process. The reliance on external heat sources during application raises concerns about increased energy consumption. As sustainability becomes important, businesses should weigh the benefits of Shrink Wrap against its environmental footprint. While providing tailored protection, the energy-intensive nature of Shrink Wrap requires careful consideration of its overall environmental impact.
Stretch Hood
Stretch Hood film is a sustainable packaging solution, addressing both energy consumption and material usage. Its unique feature of requiring no external heat source during application translates into reduced energy costs, aligning with environmentally conscious practices.
Additionally, the use of smaller and thinner film hoods contributes to overall savings in material usage. Stretch Hood is an environmentally friendly choice, offering businesses an opportunity to minimize their ecological footprint without compromising the efficiency and quality of their packaging processes.
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