In the world of logistics, warehousing and despatch operations, even the smallest increase in efficiency or an enhanced process improvement can add up to huge cost, time or environmental savings. One of these improvements could be working towards downgauging the stretch wrap used to wrap your pallets.
So, what are the benefits and considerations you need to be aware of?
And what exactly is downgauging?
What is downgauging?
Gauge in this instance refers to the thickness of the stretch film and downgauging is the process of reducing the micron thickness of the wrap being used while maintaining or even improving the load containment.
Or in other words, downgauging means using a thinner film with higher performance to reduce plastic use and cost without compromising stability.
For organisations considering the many benefits of using thinner stretch film wrapping, the fact that this is even a possibility is down to a combination of technical advancements in film technology and production. These advanced materials mean it is possible to manufacture a high performance film that possesses an excellent combination of stretch, strength and durability.
This advanced pallet wrap is known as High Performance Film and provides excellent yield and load containment yet is made from a much thinner gauge film.
But downgauging is not without its challenges and special attention always needs to be given to the products being shipped to ensure the process of downgauging stretch wrap is indeed appropriate.
The Benefits of downgauging pallet wrap
With a range of benefits that touch so many areas of the business, downgauging when executed correctly can deliver:
Cost Savings
By using thinner film, it means more pallets can be wrapped with the same amount of pallet wrap. This results in absolute savings on packaging spend.
Sustainability
Thinner film means physically less plastic used on every pallet wrapped. This results in reduced plastic waste and a lower carbon footprint not only for you but for your customers or end users too. Due to this plastic reduction, consequently your customers have less plastic packaging waste to dispose of as well.
Improved Health & Safety with added efficiency
An average roll of a 23 micron roll of machine pallet wrap can weigh over 16 kg. Lower micron rolls of wrap, such as a 9 micron roll are comparatively lighter at just over 14kg which makes life a lot easier for workers to handle, carry and load onto pallet wrap machines, potentially reducing fatigue and improving productivity.
Reduced Storage and Transportation Costs
Thinner film takes up less space in storage and transportation, potentially leading to additional cost savings and carbon footprint reduction.
How Downgauging Works
Modern downgauged films achieve their strength through advanced manufacturing techniques:
- Multi-layer Extrusion: The combining of different types of resins in 57 layers to achieve optimal strength and stretch, as found in high performance film such as iWrap. Providing incredible strength and performance, each separate layer can be programmed with specific ‘recipes’ such as stretch capabilities, puncture resistance and tear-proof qualities resulting in a unique pallet wrap for your inventory.
- Nano-layer Technology: Some films use hundreds of nano-layers to increase strength and reduce thickness.
- Pre-stretching: Some pallet wrap is pre-stretched during manufacturing, allowing for thinner application while maintaining strength.
Considerations when downgauging stretch film
While downgauging offers numerous benefits, it’s not a one-size-fits-all solution. You will need to consider the following areas to ensure your business is able to reap the rewards without making processes and outcomes worse, especially important when it comes to proper load containment.
Load Types
Different load types may require different film strengths and material used for each wrapped load. You need to ensure downgauged film can adequately secure your specific products.
Equipment Compatibility
Ensure your existing pallet wrapping equipment is compatible with the film you should be using. Using the incorrect film on a pallet wrap machine can see some operations using huge excesses of plastic, sometimes as much as 500 grams of film to wrap an average pallet. Best Practice is somewhere closer to 98 grams. Some machines may require adjustments or upgrades, your packaging expert will be able to guide you on this.
Training
Application technique becomes even more crucial with thinner films. To really get the most out of downgauging, it really is worth investing in training for your staff to ensure optimal usage. A Best Practice expert can support your team, building knowledge and know-how on how to recognise the right film for your products and equipment – capturing all the potential savings downgauging offers.
Teams working with traditional higher gauge films may need to re-learn processes to help them to use less film when pallet wrapping.
Wholistic Approach
Don’t just focus on film micron. Consider the whole process of wrapping to Best Practice to optimise stretch, wrapping patterns and containment force. This approach will enable significant plastic reductions – delivering the downgauging you need.
Implementing the process of downgauging of your pallet wrap
- Calculate Your Current Usage: To measure is to know! Work towards a deep understanding of your current film usage, costs, and performance metrics important to your business.This could be load stability data, instances of poor product protection, or pallet wrap failure resulting in refused deliveries due to damaged pallets.
- Work with Best Practice Experts: Work with a supplier who are transit packaging and pallet wrap specialists who can provide a complete Health Check on your entire palletising operation, as well as conducting testing with a range of downgauged film options.
- Analyse Results: Best Practice experts will look at a range of results from both performance and cost metrics to determine the optimal solution for your set-up. They would have considered your products, appropriate film types and all stages of the packaging cycle. From this it’s possible to identify which products can be wrapped with a lower film gauge.
- Continuous Monitoring: Regularly assess performance and adjust as needed. Again, your Best Practice expert will work with you and over time can ensure everything stays on track from ongoing training, keeping you advised of future advancements, or if something changes such as an addition of a new stock line and requires a different wrapping solution.
Conclusion
Downgauging pallet wrap offers a compelling opportunity to reduce costs, improve sustainability, and enhance efficiency in your logistics operations. However, it’s crucial to approach downgauging strategically, considering your specific needs and conducting thorough testing.
By carefully implementing a downgauging strategy, you can achieve significant benefits while maintaining and most likely improving load stability. As with any operational change, the key lies in thorough planning, testing, and ongoing optimisation for the whole packaging operation.
Downgauging has helped companies completely streamline their pallet wrapping process such as reducing the need for frequent film roll changes.
Remember, the goal is not just to use less material, but to create a more efficient and sustainable packaging process that meets your specific needs. With the right approach, downgauging can be a win-win for your bottom line and the environment.
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