Oil/Lubricant Blender/Bottler Manufacturer

SSNA Team Experts Involved: Packaging Engineer, Stretch Film Product Specialist, Packaging Account Manager

Challenge:

• Automatic Palletizer Robot investment of 250k operating at 65%

• Possible Investment of 150k - Accumulation Conveyor Project to improve throughput because Stretch Wrapper could not keep up with production levels.
• Current 20”x5000’ 90 Gauge Film is Soft for application and causing containment issues with shifting product/Top load Containment Failing
• Cost per roll $42.95
• Wrap Time: 2.28 minutes
• 32 Revolutions to wrap pallet
• Loads per roll: 41
• 20” film being applied with 30” rollers on Stretch Wrapper
• PreStretch 255%

SSNA Solution:

• Higher Performance lower gauge Paragon Film: 70 gauge 29.5”x6500’ to reduce revolutions, reduce film usage, reduce roll change time, sustain roller life ($600 EA) by 2/3rds
• Adjustment to tension and photo eye on Stretch Wrapper to amplify top load containment
• Potential retrofitting Stretch Wrapper with manual roping bar

Results:

• Improved Automatic Palletizer Optimization from 65% to 88%
• Reinforcement of Top load containment while reducing wraps from 7 to 4 revolutions
• Overall Pallet revolutions reduced from 32 to 17 revolutions
• Reduced Pallet wrap time from 2.28 minutes to 1.29 minutes
• Sustainability Improvements: Film weight reduced from 14.20 oz per pallet to .828 oz per pallet/loads per roll improved from 41 to 99 loads per roll of film
• Cost per pallet reduced from $1.05 to $0.83

No need of additional investment for conveyor system needed to increase productions throughput/Customer was running two 8 hour shifts unable to meet production goals, maximize equipment, or maximize load containment. SSNA estimated film cost savings: 29%, Labor: Scaled production back to 1 shift vs. 2, Sustainability Improvements: Reduced film usage by 42% while Improving Load Containment Issue