Improving your stretch wrapping processes enhances your overall packaging line. An efficient workflow streamlines operations and saves both time and money, while consistent wrapping creates secure loads and minimizes the risk of employee accidents or product damage throughout the rest of your supply chain. It’s clear that investing in your secondary packaging operations is critical to your company’s success.
But the world of stretch wrapping can be intimidating, especially when you’re just starting out. Don’t let daunting details, language, and decisions keep you from optimizing your packaging line. Familiarize yourself with the stretch film terminology you should know and learn your way around the different options and solutions available for your business.
Manual Wrapping
Manual wrapping or hand wrapping is the process of wrapping pallet loads by hand without the use of stretch wrapping equipment. Hand wrapping uses smaller and lighter rolls of stretch film to make it easier for employees to maneuver. In most cases, manual wrapping is an outdated practice with several drawbacks. It is slower and less consistent than machine wrapping. Additionally, employees can’t achieve the same amount of pre-stretch or film tension that a stretch wrapping machine can. Hand wrapping at best provides 10% to 30% stretch. Automating with a stretch wrapper provides from 200% to as much as 500% pre-stretch, depending on the machine and film being used.
Hand wrapping also puts employees at risk of repetitive strain injuries from constant bending, lifting, twisting, and pulling as they work around dozens of product loads each day. Manual wrapping is a physically strenuous job that significantly increases your chances of workplace injuries, employee burnout, and other problems. Recent studies show that a “medically consulted injury” average cost is almost $50,000 per injury.
Machine Wrapping
Machine wrapping is a more efficient, consistent, and productive solution to stretch wrapping. With the use of automatic and semi-automatic wrapping machines, you can streamline your packaging line and better secure your product loads as they move through the supply chain.
Automatic wrapping machines are powerful and highly efficient solutions for businesses that work with a high volume of orders. These machines move product loads into and through the wrapping stage via conveyors with zero employee intervention, enabling smooth, fast, and reliable operations day in and day out.
Depending on the level of automation, semi-automatic stretch wrappers also improve consistency and efficiency, but they do require minor employee intervention in most cases. You might need operators to deliver or take away product loads, press a start button, attach or cut film, or perform other tasks. Because of this need for employee supervision, semi-automatic stretch wrappers are better suited for lower-volume facilities (less than 30 pallet loads per hour) that don’t rely on high-speed, high-capacity packaging solutions.
Turntable Stretch Wrappers
There are many different types of automatic and semi-automatic stretch wrappers, each with a unique design that offers special advantages for various types of product loads. One of the most common solutions is a turntable stretch wrapper, which uses a rotating turntable and film delivery systems to wrap pallet loads. Turntable stretch wrappers are a quick and efficient way to wrap stable loads that won’t tip or break with the rotating motion of the turntable.
Rotary Arm Stretch Wrappers
In some ways, rotary arm stretch wrappers are the opposite of turntable stretch wrappers. With this type of stretch wrapper, the product load remains still on the floor while the rotary arm moves around the load and wraps it. This method is ideal for fragile loads that are too unstable for a turntable wrapper. It also works well for heavy loads that are difficult to move and rotate during the wrapping process.
Robot Stretch Wrappers
Robot stretch wrapper machines are ultra-efficient, ultra-portable stretch wrapping solutions. These compact and agile machines bring the wrapping stage to the product load rather than the other way around. Robot stretch wrappers can wrap pallet loads that are any length, width, or weight (over 200 lbs.). Solutions like the Robopac USA Robot Master mobilize the stretch wrapping process to keep your packaging line fast, flexible, and productive.
Horizontal Stretch Wrappers
Not all products fit onto traditional pallets, which means not all product loads work with vertical wrapping machines. That’s where horizontal stretch wrappers come in. These machines move products along conveyor belts through a rotating ring that applies the stretch film. This allows long or awkwardly shaped products—like pipes, insulation boards, lumber, and more—to move efficiently through the stretch wrapping stage.
Stretch Film
Not all stretch film is created equal. Using the correct type of stretch film helps you create the safest, most cost-effective product loads. There are four main types of stretch film: cast film, blown film, true gauge film, and pre-stretch film.
Cast film is a glossy, transparent film that is easy to unwind and manipulate. Manufacturers create cast stretch wrap by shaping molten plastic or resin onto cooled rollers. Cast film is a thinner form of stretch wrap, so it’s an ideal lightweight solution for lighter loads. Blown film, on the other hand, is a tougher form of stretch wrap that offers more protection and stability for heavy-duty loads. Manufacturing blown stretch wrap involves using air to shape the molten resin into a flat, collapsing tube.
True gauge stretch film is a consistent form of stretch wrap with a precise thickness. This level of accuracy and precision allows manufacturers to maximize the stretch of the film and create more consistent wrapping. Finally, pre-stretch film is a type of true gauge film that manufacturers stretch before wrapping it around the film roll. The pre-stretch process allows the film to go farther, making it an efficient and sustainable option.
Film Gauge
Another stretch film term you should know is film gauge. The gauge of the film refers to the thickness of the stretch wrap. The higher the gauge level, the thicker and stronger the stretch wrap is. However, a higher gauge isn’t necessarily always the right choice. Lighter gauge wraps make for lightweight loads that are more breathable and easier to work with. It’s important to choose the right gauge according to your specific products, pallet size and weight, and other specifications.
Pre-Stretch Carriage
The pre-stretch carriage is the part of the stretch wrapper machine that stretches the film before applying it to a load. It passes the film through two rubber rollers to pre-stretch it before wrapping it around a pallet. Investing in a stretch wrap machine with powerful pre-stretch capabilities—like Robopac USA’s Cube Technology, which offers up to 55 percent film savings—helps you achieve adequate containment force with less material. The result is a more efficient, cost-effective, and sustainable pallet wrapping process.
Robopac USA is your go-to supplier for industrial stretch wrapping equipment. Explore your options and implement optimized solutions for your facility when you work with our team today.
