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Whether your products travel by land, sea, or air, they run the very real risk of being damaged while in transit. Packaging Digest reports that anywhere from 2% to 11% of all shipments incur some form of damage by the time the products reach their final destination
Shipping products from point A to point B can be a risky journey. Vibration, impacts, and mishandling can easily damage goods along the way.
A semi or fully-automatic pallet wrapping machine helps prevent product damage'especially when wrapping pallets by hand.
Read on to learn how to properly shrink-wrap a pallet and keep your goods safe and secure.
Use common sense and avoid overloading the pallet to save on shipping. Stacking too high can create an unstable load that is hard to wrap and secure properly. Following pallet wrapping guidelines for maximum load weight and height will ensure a secure wrap.
Before wrapping, check the load stability by calculating the pallet's capacity. Ensure the products' total weight and height do not exceed the pallet's load limits. Use more stretch wrap for heavier, less stable loads. The more the products shift or lean, the more you'll need to secure them.
Once the pallet is on the shrink wrapper, you'll need to attach the film to the pallet. The best attachment point is in the lower corner of the pallet, further away from the carriage. Automatic pallet wrappers perform this step automatically, so workers don't have to get off the forklift.
After you've attached the film, head over to the pallet wrapper control panel and make the following adjustments:
Revolution speed'Set the revolution speed appropriately. Too fast may topple the load, but it should still wrap quickly enough for production needs. Find the right speed that secures the products without slowing down wrapping.
Carriage ascent and descent speeds'Assess the pallet height and weight. Then adjust the carriage ascent and descent speeds accordingly:
The goal is to optimize the speed to use just enough wrap to fully secure the load without wasting excess. Watch the coverage and adjust speed as needed.
Film force tension'Properly setting the tension is critical for a quality pallet wrap. Be careful not to over-tighten the pressure to prevent damage. This can lead to film tearing or crushed boxes on the bottom layers.
Start with moderate tension and observe the results. Adjust as needed based on the load weight. Use lighter tension for lighter loads to avoid damage. Increase tension for heavier loads to contain them securely.
*Note: Machines with the power pre-stretch feature tend to need less film force tension because it has memory. It will constrict back to the load after passing through the rollers.
Photo-eye delay setting'There is a control setting that causes the film to curl over the top of the load. Typically, for an A-load, you'll want around 3-6' of overwrap to help contain the uppermost boxes on the pallet.
Assess the uniformity and weight of the pallet load. Then adjust the photo-eye delay setting accordingly:
Watch the overwrap as you test your settings. Adjust the delay until you reach the proper overlap for the specific pallet.
For a standard pallet of boxes under 2,000 pounds, set the top and bottom wrap settings to about three revolutions. This should be enough to secure lighter loads. If you need to apply more wrap, try to avoid overdoing it. You'll wind up wasting time and money and won't see an increased benefit.
Perform an initial test wrap for the first pallet load. Yes, it might take a little longer at first. However, you'll know exactly how fast or slow you must go when wrapping similar pallets.
Generally, it is better to start with slower speeds for both the turntable and the carriage. Gradually increase the speeds in small increments to find the optimal settings and ensure a safe and secure wrap.
Setting the tension at about halfway is a good starting point unless you have fragile boxes. In that case, start at around 20%. You'll eventually get a sense of optimizing the cycle time and balancing the appropriate amount of wrap film.
Once the test wrap completes, pay particular attention to the bottom wraps to help secure the load to the pallet. Extra top wrap revolutions can also be helpful for unstable loads.
Finally, check the overall stability of the wrapped pallet. Does it seem stable and well-protected? If not, go back and adjust the stretch wrapper settings further. If so, cut the film and wrap it around the base of the pallet.
The Model Series semi-automatic stretch wrap machine cuts and tucks the wrap into the base of the pallet automatically. Automating this final step saves time and allows the operator to remain on their forklift.
See how quick and easy it is to securely wrap a pallet with the Handle It Model 850PS shrink-wrapping machine..
When it comes to wrapping a pallet of boxes with a pallet wrapper, there are several things that you can do that will help ensure a successful and secure wrap. Read on to learn more about how to properly shrink wrap a pallet and keep your goods safe and secure.
When initially loading the pallet with your products, let common sense be your guide. Don't try to stack too many boxes to save a few bucks on shipping costs. You could potentially create a situation where you're hoping the wrap job will somehow be able to overcome the laws of physics.
Before you load the pallet onto the pallet wrapping machine, assess how stable your products are by learning how to calculate pallet load capacity. A general rule of thumb is that the heavier and less stable the load, the more stretch film you should apply.
After you've loaded the pallet with boxes and placed it onto the pallet wrapping machine, head over to the control panel on the pallet wrapper and make the following adjustments:
Revolution speed ' set this to an appropriate level. Too fast, and you can run the risk of toppling the load'however, you still want it to be fast enough to keep up with your production.
Carriage ascent and descent speeds ' you should set them to optimize the film coverage throughout the load height. If you have the speed set too fast, you can leave uncovered gaps. Too slow, and you can be wasting film. Again, this depends on the pallet's weight and stability' with more film needed with heavier and unstable pallets.
Film force tension ' is another basic setting that you will want to dial in for a proper pallet wrap. Set the film force tension so that the film applied holds to the product but not so tight that you crush the load. Keep in mind that if you set it too tight, you can run the risk of film tearing, which can cause time delays or crushed boxes.
*Note that machines with power pre-stretch tend to need less film force tension because the film has memory and will constrict back to the load after being stretched through the film rollers.
Photo-eye delay setting ' A setting within the controls allows you to get the film to curl over the top of the load. Typically, for an A-load, you'll want around 3-6' of overwrap to help contain the uppermost boxes on the pallet.
As a general rule of thumb, a standard load of boxes that weighs less than 2,000 lbs shouldn't need more than ~3 revolutions for the top and bottom wrap settings. Certainly, there are situations where you need to apply more film but be cautious not to waste time and money with too much stretch film.
For the first pallet load, you should perform an initial test wrap. Yes, it will take a tiny bit longer, but once you get things dialed in, you'll have a good idea of just how fast (or slow) you need to go when wrapping subsequent pallets.
In general, it is better to start with slower speeds for both the turntable and carriage and then incrementally work up to faster speed. This will help reduce the chance of film tearing on the pallet or load and give you a better idea of how much film to apply.
Typically, setting the tension at about halfway is a good starting point unless you have fragile boxes. In that case, start at around 20%. Once you've wrapped a few pallets, you'll get a sense of how to optimize the cycle time and balance the appropriate amount of film.
Once the wrap is complete, pay particular attention to the bottom wraps to help secure the load to the pallet. Extra top wrap revolutions can also be helpful for unstable loads.
Learning the correct way to use your wrapping machine will help ensure a safe and secure loading experience'and a happy customer. If you have any questions about wrapping your pallets or your current pallet wrapping machine isn't up to par, contact us today to learn more about how Handle It can help solve your toughest wrapping challenges.
The amount of stretch wrap required depends on using pre-stretched or non-pre-stretched film. The pre-stretched wrap contains built-in tension and uses less material. Non-pre-stretched requires more revolutions and wrap to create tension around the load.
The weight, size, and consistency of the load you're wrapping also play a factor. There are different types of stretch film to consider as well.
For a typical 40×48 inch pallet stacked around 5 feet high, you would need approximately 100-150 feet of non-pre-stretched film. However, with a pre-stretched carriage, you may only require 30-40 feet for the same size load.
This is due to the pre-stretching mechanism stretching the film as it applies it. This allows it to cover more area with fewer linear feet of wrap. Pre-stretching can dramatically reduce total wrap usage for the same coverage.
You should strap pallets before stretch-wrapping them. Strapping first provides load stability and compression. Then you can apply the stretch wrap over the straps to seal and contain the pallet. Strapping before wrapping also helps optimize pallet integrity for shipping and handling.
The number of wrap revolutions depends on the box size and weight. Uniform, lighter loads need 2-3 revolutions. Heavier or irregular loads require up to 4 revolutions to stabilize the pallet. Using more than 4 revolutions wastes film with little added benefit.
Generally speaking, avoid wrapping the same section more than 2-3 times. Instead, do 2-3 low wraps to stabilize the bottom, then 2-3 higher wraps to seal the top. Four total revolutions (2 down, two high) secure most pallets well without excessive wrap use.
Adjust the photo-eye delay to ensure complete coverage when wrapping irregular-sized loads. Start with a longer delay to prevent an early cutoff at the top. Watch the wrap and refine the setting for a proper top overlay.
Use lighter tension settings initially on uneven loads to avoid wrap breaks. Progressively increase tension for better hold without crushing contents. For tall pallets, slow the carriage speed to cover the height fully. Thicker film or lighter tension prevents punctures from sharp edges.
Taking the time to dial in a stretch wrapping machine properly pays off through securely wrapped pallets and damage-free shipping. Get in touch with us below to learn how Handle It can help solve your toughest wrapping challenges.
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Comments:
a) In semi-automatic wrappers, there is a typically a 'Start' pushbutton.
b) In automatic equipment, select 'Auto' on the main control panel, or if a load is already in place, push the 'Rewrap' pushbutton.
Comments:
a) The turntable speed is the first thing to be set in the controls because several of the following steps are affected by this setting and all would need to be re-set if this is changed.
b) Most wrappers have a maximum turntable speed of anywhere from 10 to 15 RPM.
c) Some wrappers come with this value preset from the factory, while others use a speed dial or operator selector of some kind on the control panel of the machine.
d) Some wrappers (typically automatics) have this speed controlled by settings directly on the drive board or in the PLC program.
e) We recommend not running the turntable at full speed unless the loads are very stable (before being wrapped).
f) Rotary arm wrappers do not run the risk of loads falling apart due to rotation speeds, but something less than full speed is still recommended.
Comments:
a) This setting controls the amount of tension (aka. post-stretch) that is put on the load after the film comes out of the film carriage.
b) In a machine equipped with pre-stretch, the film has already been stretched inside the film carriage, and will naturally tighten on the load as it sits there over the next few hours, so this setting doesn't usually need to be set to a very high value.
c) Establish this setting before proceeding to the next step because as the tension is increased, the film will 'neck down' more and more, narrowing the film web, and affect the amount of film coverage on the load with each revolution.d) Check the loads after they have been wrapped and been sitting in storage for a few hours (or days). If the product is susceptible to crushing, and this setting is too high, there may be damage to the load. If so, reduce this setting. Trial and error with the settings of the wrapper, and the proper selection of film, will help to produce satisfactory long term results.
Comments:
a) The intent of this setting is to completely cover the product for cleanliness and theft deterrent purposes but apply as little film as possible.
b) Setting this speed as high as possible (while maintaining overlap) minimizes the time it takes to reach the top of the load (decreasing cycle time, increasing load throughput, and minimizing film costs).
Comments:
a) This setting controls how much extra time the film carriage raises above the top of the load after the Auto Height Photoeye senses the top of the load.
b) Many film carriages have a means to mechanically adjust the position of the photoeye to adjust this.
c) Other film carriages use a timer in the control system to cause the film carriage to keep raising after the photoeye senses the top of the load. In semi-automatic wrappers this timer is usually operator adjustable using the control panel. In automatic wrappers, this value is often programmed into the PLC.
d) Many wrappers have both of the above means to make this adjustment.
e) On a turntable style wrapper, if the load is taller than the wrapper is built for, the film carriage will stop raising when the film carriage reaches the maximum upper limit of travel possible, and the film will not wrap over the top of the load. In this case, the settings for overwrap have no effect, and the wrap cycle will carry on without issue.
f) If the top layer of a load is not complete, and there are extra boxes (products) left over, build the top layer of these loads such that these extra boxes (products) are placed in the corners and/or the outside edges of the load. Then, increase the overwrap setting (beyond the 4" recommendation) such that the film carriage raises an amount sufficient to catch these extra boxes (products) and secure them with the wrap.
Comments:
a) This setting controls how many revolutions the load (or the tower) will continue to rotate after the film carriage is at the top of the load, and before the film carriage starts to lower.
b) Two (2) top wraps is the recommended minimum for this value because it guarantees at least one full revolution of film at the top. (Explanation - Considering that there is a delay in time for the stretch film to actually reach the top of the load after the film carriage stops raising, if this value is set to only one (1), it is conceivable that the film carriage could count one revolution and start lowering before one complete wrap has actually occurred at the top of the load.)
c) Note that a significant portion of the load unitization that keeps the loads from falling apart during transport is provided by the top wraps on the load. Therefore, if extra load retention is required, the single most significant setting to be changed is the top wraps count.
d) Most wrappers allow up to nine (9) top wraps to be applied, however, rarely is there a need to go beyond a count of four (4) top wraps. Industry practice finds that four (4) top wraps is fairly significant, and applying any more than that simply drives up the packaging costs, increasing wrapping time, and reducing throughput.
Comments:
a) This setting controls how fast the film carriage lowers to the bottom of the load, following the completion of the top wraps.
b) Since the load has already been secured by the wrap during the film carriage raise portion of the cycle, and structurally secured during the application of the top wraps, there is no need to manage overlap, and the film carriage can go to the bottom as fast as possible in order to minimize wrap cycle time, and reduce film usage.
c) However, if extra load retention in the middle of the load is required, slowing the film carriage down with this setting will apply extra film to the middle of the load and improve the integrity of the load. Note that slowing this down more than necessary only increases packaging costs and slows down the cycle time of the wrapper.
d) Changing this setting (instead of changing the film carriage up speed) to improve load retention in the middle of the load is preferred because changing this setting does not force the overwrap settings to be re-set.
Comments:
a) This setting controls how many revolutions the load (or the tower) will continue to rotate at the bottom of the load after the film carriage has reached the lower limit, and before the turntable (or tower) shifts into slow speed to park at the start (home) position.
b) Two (2) bottom wraps is the recommended minimum for this value because it guarantees at least one full revolution of film at the bottom.
c) These wraps help to secure the load to the pallet so it doesn't shift in transit.
d) Most wrappers allow up to nine (9) bottom wraps to be applied, however, rarely is there a need to go beyond a count of four (4) bottom wraps. Industry practice finds that four (4) bottom wraps is fairly significant, and applying any more than that simply drives up the packaging costs, increasing wrapping time, and reducing throughput.
Comments:
a) After the largest test load has been satisfactorily set up, then repeat the process with the smallest test load.
b) Adjustments to the settings may be required and through trial and error the best settings can be found.
c) If the wrapper is equipped with a 'quick select', 'wrap program', 'independent settings switch', 'pattern selector switch', 'multiple wrap settings', 'recipes', etc. feature, it could be possible to set up another wrap program to better suit this smaller load size.
Do not assume that all settings are necessarily optimized to your needs after your initial set up. Monitor your loads on a regular basis, from the time of wrapping, while they sit in your warehouse, to when they are put onto trucks for shipment, and after they have arrived at your customer's location.
The type of stretch film that you are using may also be optimized. Work with your film supplier on a trial and error basis to optimize your wrapping efficiency, and reduce your materials costs while maintaining load integrity during transport.
There is another way of setting up your wrap pattern, which typically works just as well, and the use of which is a matter of preference. This alternate pattern has the film carriage raise to the top as fast as possible, and then has the film carriage lower at a speed which provides the desired overlap of film.
If wrapping for outside storage, one would typically wrap with overlap (i.e. raise slowly) to the top, pause the wrap cycle, apply a top sheet, then resume the cycle during which the top sheet gets wrapped in by the top wraps. This produces a 'water-proof' wrap.
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