Blog Posts & Case Studies
In today's environmentally conscious business landscape, reducing plastic waste has become a crucial goal for many companies. One area where businesses can make a significant impact is in the method used to wrap pallets. Whether wrapping pallets by hand or using a machine, each method has its own set of advantages and disadvantages that can influence not only operational efficiency but also environmental footprint.
Manual wrapping offers cost-effectiveness and flexibility, making it an ideal choice for smaller operations. It doesn't require expensive machinery or extensive training, and it saves space in the warehouse. However, it can be labour-intensive, inconsistent, and pose safety risks due to its manual nature.
On the other hand, machine wrapping offers consistent tension, enhanced efficiency, minimised physical strain on workers, significant cost savings and reduced plastic use. Although it requires substantial initial investment, maintenance expenses, additional space, and training, its benefits are substantial for high-volume operations.
Choosing the right method for your business involves weighing these pros and cons carefully, especially to reduce plastic waste and improve sustainability. This blog post will help you in your decision.
When securing pallets manually, the choice between cast and blown pallet wrap can significantly impact efficiency and cost.
Megastretch cast hand film and Blackshield opaque black film
Conventional pallet wrap is made by feeding plastic resin through rollers to form a thin, clear film. This wrap allows for easy content identification and barcode scanning. It unwinds quietly and offers good tear resistance and cling properties, making it strong and reliable. Its high clarity ensures easy inspection of wrapped goods and it is cost-effective to produce. However, it requires more manual effort to stretch and is heavier, potentially increasing shipping costs.
Pre-stretched pallet wrap is stretched during manufacturing, and features a thin adhesive coating, making it easier to apply and reducing worker fatigue. It uses less material, providing high tension for consistent load stability. This wrap is lightweight, efficient, and environmentally friendly due to less waste. Although it is more expensive per roll and may have lower puncture resistance, it offers significant ease of use and material efficiency.
The Grip system and available films
The Grip pre-stretched pallet-wrapping system stands out as an exemplary solution revolutionising the industry. Featuring a brilliant Grip Applicator and high-quality Grip Film, this manual wrapping system significantly enhances load stability, material efficiency, speed, and productivity. It also offers ease of use, long-term cost savings, wrapping consistency, and improved worker safety. These exceptional benefits result in more efficient, reliable, and sustainable shipping operations.
Machine pallet wrapping is a more complex topic compared to manual pallet wrapping. We will focus on the most commonly used types of machines and film so that you can choose what is best for your business.
There are various types of machines, but the most commonly used pallet wrappers are the turntable, the rotating arm, and the self-propelled robots. The turntable and rotating arm machines are stationary and should be placed in an accessible area where palletized goods can be easily placed to be wrapped. On the other hand, the self-propelled robot is more versatile, as it can wrap a pallet practically anywhere, provided there is enough space for it to operate safely.
From left to right: ROBOPAC's EcoWrap, EcoPlat, and Robot Master Plus
Now that you have selected the appropriate machine for your operation based on the available space and layout, you need to decide whether you require a machine with a carriage that allows you to pre-stretch the film. This decision is crucial as it will significantly impact the type of film you can use, leading to a reduction in plastic usage and, subsequently, costs.
A machine like the more affordable ECOPlat Plus, which is a turntable pallet wrapper, allows you to use any type of machine film. However, since it does not have a pre-stretch carriage, you can only stretch the film up to 150%. On the other hand, if you choose the MasterPlat Plus, also a turntable pallet wrapper, you can fully utilise a film that can stretch up to 250%.
The pre-stretch carriage of a pallet wrapping machine on the left and its control knobs on the right.
To better understand the film's yield, let's use 1 meter as a reference. If we stretch 1 meter of unstretched film to 150%, it will be converted into 2.5 meters. Stretching 1 meter to 250% will convert it into 3.5 meters.
Machine pallet wrapping film is available in various thicknesses, typically ranging from 8 to 34 microns (mu), with the most common options being 17mu and 23mu. These films are categorised as Standardor Power Pre (PP). Standard film has a maximum stretch capacity (yield) of 150%, while PP film can typically be stretched up to 250% or more. However, to achieve this level of stretching, you need a machine with a pre-stretch carriage, such as the MasterPlat Plus or the Robot Master Plus.
Opaque and clear machine pallet-wrapping film
It's important to consider a few things when trying to reduce plastic use and minimise costs for pallet-wrapping film, which is typically sold per kilogram. Finding the right balance between film thickness and yield is crucial for optimising your operations and reaching your sustainability objectives. One effective solution is to opt for a 17-micron PP clear film (unless an opaque solution is necessary). This type of film is lighter than the 23-micron film and has a 300% yield, allowing you to fully utilise the pre-stretching carriage system of your machine.
Another important factor when choosing film is the type of pallet that you are wrapping. Is it a square (A), irregular (B) or protruding (C) pallet? The table below will help you in your decision:
| Film | Square Pallet Type A | Irregular Pallet Type B | Protruding Pallet Type C |
| 20mu 150% Yield | 🟢 | 🟡 | 🔴 |
| 17mu 300% Yield | 🟡 | 🟡 | 🟢 |
| 23mu 250% Yield | 🟡 | 🟡 | 🟢 |
Deciding on the right pallet-wrapping method can be challenging. While hand-wrapping may seem like a good starting point, machine-wrapping is the most efficient way to minimise plastic usage and reduce costs in the long term. The choice between the two methods depends on the type of goods, pallet, and shipping frequency.
At McKinleys, we have decades of experience and have learned from some of the largest fulfilment companies in the UK. We can provide you with guidance and evaluate your packaging process to help you achieve your sustainability objectives without exceeding your budget.