Stretch wrapping is a crucial step in protecting your goods during transit, but failure to properly unitise a load can result in significant damage, wastage, and added costs. In this article, we’ll explore six common factors that contribute to load failure, and how you can avoid them.
Our goal is to help you achieve the perfect stretch wrap, and understanding these causes is the first step. So, let’s dive in!
The Evolution of Packaging Systems
Packaging systems are generally broken down into three levels: primary, secondary, and tertiary. While our focus is on tertiary packaging, which involves the unitisation of loads to ensure products reach their destination intact, changes in primary and secondary packaging over the years have had a significant impact on how we wrap and secure loads.
Take a moment to think back to the evolution of product packaging. For example, did you know that the bumps on the bottom of Coca-Cola bottles are designed to improve stability? These clever design features strengthen the bottle and ensure that the centre of gravity remains lower, making palletising more stable. It’s a simple yet effective solution with a big impact on the entire supply chain.
So, why is this important? As we move forward, we’ll explain how these design principles apply to stretch wrapping.
Understanding Load Types for Shipment Configuration
When preparing loads for shipment, it’s crucial to choose the right stretch film and wrapping technique based on the load type. There are three primary load types:
- A: Uniform with clean edges
- B: Irregular load with uneven edges
- C: No conformity with sharp edges
Each type requires a different approach to ensure the load remains stable. The key goal in all cases is to achieve unitisation, which equals a stable load, fewer damaged goods, less wastage, and ultimately lower costs.
Common Causes of Load Failure
Now that we understand load types, let’s take a closer look at six factors that can cause your stretch wrapping to fail.
1. When the Marriage Goes Wrong
The combination of the right pallet wrapping machine, film, and load is like a marriage — they need to work together. You can’t simply rely on the best machine and best film to achieve a stable load. The key is understanding how each component works with the others to deliver the best result.
Ask yourself these and more
- What type of load am I wrapping?
- What are the film properties required?
- How far can I maximise the film?
- What is the most suitable wrapper for my load and film types?
- Can I get the optimum stretch out of my existing film?
2. When Limits Are Overstretched (or Understretched)
Stretch film has limits, and exceeding them can lead to breakage or poor load containment. Overstretching can cause film breakage during wrapping or transit, while understretching can result in uneven wrapping and waste. Knowing the optimal stretch for your film will ensure consistent, repeatable results.
Again you will need to understand.
- What are the properties of your film?
- How do you know the limit thresholds of your films?
- What is the optimum stretch and working zone of your film?
- At which resolution is enough to give your load the best support where the rest are unnecessary wastage?
- How do I ensure consistent wrapping that is repeatable?
3. When Assumptions Lead to Poor Choices
A common mistake is assuming that thicker films always perform better. For example, many people still use heavy gauge films like 23um, 25um and 30um for heavy loads, believing thicker is always better. But sometimes a thinner film can provide the required strength at a lower cost. Thicker film does not necessarily mean better holding force or a more stable load.
Often heavier gauge films are made with old technologies, poor materials and poor quality control form substandard importers and manufacturers. But switching to a high quality thinner film could be beneficial
4. When the Load Shifts During Wrapping
If your load shifts while being wrapped, it’s likely because the machine settings or the load’s integrity aren’t optimal. This can lead to poor unitisation, which makes the load more susceptible to damage during transport.
5. When Downgauging is Done Incorrectly
Downgauging — or using thinner films to cut costs — can backfire if not done with consideration of the load type and film properties. While it’s tempting to cut costs, failing to properly match the film to the load can lead to inferior unitisation and increased risk of damage.
When Bonding is Weak
Optimising Your Stretch Wrapping Process
To achieve optimal stretch wrapping, it’s essential to address these common failure factors. While the best machine and film won’t guarantee success on their own, understanding how to match these elements with the specific needs of your load is critical.
Effective communication and knowledge-sharing among all supply chain stakeholders is key to improving packaging outcomes. When you work together and share insights, you can achieve better load protection, reduce injuries, minimize damage to goods, and contribute to sustainability goals.
The Formula for Successful Stretch Wrapping
At MPS Packaging, we believe that solving these common issues starts with education and understanding. By optimising your stretch wrapping process, you can:
- Reduce injuries and accidents related to load failures
- Lower costs by minimising damage and wastage
- Achieve sustainability goals and contribute to your company’s ESG initiatives
If you’re ready to take your stretch wrapping to the next level, MPS Packaging is here to help.
