How to save money on pallet wrapping?
31/12/2023
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Hand wrapping pallets becomes uneconomical as their processing increases. The manufacturing and distribution industry signals issues with delayed shipment, high material costs, and resource challenges in the pallet wrapping process.

It’s easy to imagine the scale of savings that can be achieved in manufacturing plants and distribution centers processing hundreds of thousands or even tens of thousands of pallets annually.

Issues in production and distribution centers

As a company collaborating with distribution centers, we have seen the significant impact of pallet shipping time, the way it is prepared for transport, as well as the planning of adequate internal logistics and space management. The proper placement of goods in the warehouse, pallet completion time, moving it to be wrapped with stretch film, and the working time of the wrapping staff or automatic wrapper are all crucial factors.

With a large number of processed pallets, every second can be considered as valuable as gold. For manufacturing plants, the proper placement of machines to effectively integrate processes and save space is also essential. Nevertheless, the quality of the product and its packaging are crucial to avoid damages during transportation.

Manufacturing plants and distribution centers processing a large amount of goods must constantly seek optimization in various processes, and one of them is preparing pallets for shipment. Neglecting the optimization of pallet wrapping can result in inadequate protection for some pallets, a higher customer complaint rate, increased costs, or an extended pallet preparation time.

Is an automatic pallet wrapper necessary?

The period of increasing efficiency in manufacturing processes is crucial for the facility. Similarly, the time when a distribution center improves the efficiency of goods picking. It must be remembered that if we increase the efficiency of these processes, we will also need to speed up pallet wrapping or increase the storage space for pallets waiting to be wrapped.

How can we solve the “issue” of increasing efficiency?

Increase the number of engaged workers or work hours:

This would work for single- or double-shift work, as with three shifts, the number of pallets waiting to be wrapped would accumulate, and sooner or later, there wouldn’t be enough space in the warehouse. However, even with double-shift work, with a sufficiently large space for pallets before wrapping, we extend the preparation time for pallets for distribution. They wait to be wrapped instead of waiting ready in the warehouse.

Additionally, in this case, we increase costs by increasing the number of workers or extending their working hours.

Decrease production/picking efficiency:

We can also decrease the efficiency of product manufacturing/pallet picking so that the wrapping process keeps up, but this limits the execution of the production plan.

Increase wrapping efficiency using automatic or semi-automatic wrappers:

Increasing the efficiency of pallet wrapping seems to be the optimal solution. We don’t need additional personnel or time to prepare pallets, thus avoiding additional costs. The wrapper itself becomes an additional cost, but the return on investment in such a machine occurs even within a year. This depends on the individual case and the chosen wrapper.

These machines are characterized by repeatability, the ability to stretch the stretch film more, and savings in the film itself through optimal consumption. Moreover, this solution ensures higher product safety in transportation, minimizing the risk of customer complaints.

Considering pallet wrappers in other cases

Pallet wrappers are most effective when dealing with a large quantity of processed pallets, but in smaller production, turntable wrappers can also be suitable. Turntable wrappers are characterized by lower efficiency at a lower cost.

Additionally, as mentioned earlier, pallet wrappers are not only highly efficient (up to 160 pallets/h), but they offer various benefits:

  • Minimization of the risk of complaints due to improper securing
  • Material savings (stretch film)
  • Consistent pallet quality
  • Reduction in product shipping time
  • Increased pallet protection
  • Wrapping unevenly stacked products on the pallet
  • Streamlining processes

Summary

Optimizing the pallet wrapping process is one of the key opportunities for savings in growing enterprises in the manufacturing and distribution industries. Therefore, it is worthwhile not to overlook this possibility and consider its cost-effectiveness for your own facility.

automated pallet wrapping

In Proster’s offer, you will find ➡ Tosa pallet wrappers ⬅ providing an additional benefit – a special approach to preventive maintenance, ensuring long-term operation. These solutions generate real savings in maintenance, reaching up to 75%, and the oldest working Tosa machine has been in operation for over 35 years(!). We not only handle the sale of pallet wrappers but also take care of their installation and warranty service.

Additionally, we assist in reducing production and distribution costs and provide advice on process optimization during automation implementation.