MPS recently completed the installation of two Atlanta Stretch Synthesi PRS XF-4113 pallet wrapping machines with scales and ramps at a major Melbourne distribution centre. The new machines were supplied complete with integrated weighing scales and loading ramps, creating a more efficient pallet wrapping and dispatch process.
For a busy distribution centre, pallet wrapping is much more than simply securing a load. Every extra step adds time, and every unnecessary gram of stretch film adds cost. By combining pallet wrapping and weighing into the one workstation, this installation helps streamline the entire dispatch process while also significantly reducing ongoing stretch film consumption.
Two Synthesi PRS XF-4113 Pallet Wrapping Machines
For this application, MPS Packaging supplied and installed two Synthesi PRS XF-4113 pallet wrapping machines.
The Synthesi is a heavy-duty semi-automatic pallet wrapper manufactured in Italy by Atlanta Stretch. The XF-4113 configuration is equipped with a powered pre-stretch film carriage, making it particularly well suited to distribution centres and warehouses wrapping a consistent volume of pallets every day.
Rather than simply applying stretch film directly from the roll through afew mechnically braked rollers, the powered pre-stretch system stretches the film before it is applied to the pallet by 200%, controlled by variable speed hall card for smooth wrapping. This allows substantially more usable film to be produced from every roll while maintaining controlled tension around the load.
The result is lower film consumption, a more consistent wrap and improved load containment.
Integrated Scales – Wrap and Weigh in One Location
One of the major additions to these machines was the installation of integrated pallet scales.
In many warehouses, wrapping and weighing are two completely separate processes. A pallet may be wrapped in one location before being moved to another set of scales to determine its final dispatch weight.
By incorporating scales directly into the pallet wrapping station, the pallet can be wrapped and weighed without needing to be transferred between different pieces of equipment.
For a high-volume distribution centre, removing even a small amount of unnecessary pallet movement can add up to considerable time savings across a week, month or year.
It also provides operators with an accurate pallet weight as part of the wrapping and dispatch process, making it easier to prepare loads for freight and transport.
Ramps for Easy Pallet Loading
Both XF-4113 pallet wrappers were also installed with loading ramps.
The ramps allow pallets to be easily loaded onto the turntable using suitable lower cost pallet handling equipment without requiring the wrapping machines to be installed into a pit.
This provides a relatively simple installation while maintaining convenient access to the turntable.
When specifying a pallet wrapping machine, it is important to consider how pallets will actually be loaded and unloaded. The wrapper itself is only one part of the system. Forklifts, pallet jacks, walkie stackers, available floor space and pallet dimensions all need to be considered when designing the best solution.
For this Melbourne DC, the combination of the Synthesi machines, scales and ramps provided a practical solution that could be incorporated into their existing warehouse operation.
Powered Pre-Stretch Reduces Stretch Film Costs
One of the biggest opportunities for savings came from moving to powered pre-stretch pallet wrapping.
Powered pre-stretch physically stretches the film between rollers inside the film carriage before it reaches the pallet. This means the machine can produce considerably more usable metres of film from the same roll.
For businesses wrapping large numbers of pallets, this can make a significant difference to the cost of wrapping each pallet.
It isn't simply about using less film either.
A good powered pre-stretch machine provides greater control over how the film is applied. This can produce more consistent containment force from pallet to pallet and reduce the variation that can occur with manual wrapping or basic friction-brake machines.
For a distribution centre sending out large numbers of pallets, consistency is extremely important. A poorly wrapped pallet can potentially cost far more in damaged or unstable goods than the stretch film used to wrap it.
Further Savings by Switching to MPS Pallet Wrap
The machine upgrade was only one part of the opportunity to reduce the customer's packaging costs.
MPS Packaging was also able to review the stretch film being used through the machines and switch the customer across to MPS machine pallet wrap.
The combination of the correct film and a powered pre-stretch machine is important. Simply installing a better pallet wrapper does not automatically guarantee the lowest possible cost per pallet.
Film specification, roll weight, film thickness, pre-stretch percentage, force-to-load and the wrapping program all influence how much film is ultimately consumed.
By looking at both the machine and the consumable, MPS was able to help reduce the customer's ongoing wrapping costs rather than focusing only on the initial machinery purchase.
For a high-volume DC, even a relatively small saving per pallet can become substantial when multiplied across thousands of pallets.
Better Wrapping, Lower Film Consumption
This installation demonstrates why upgrading pallet wrapping equipment can provide benefits well beyond simply making the wrapping process faster.
The two Synthesi PRS XF-4113 pallet wrappers give the Melbourne distribution centre a more controlled and repeatable wrapping process, while powered pre-stretch technology helps reduce the amount of stretch film required.
The integrated scales allow pallets to be weighed during the same process, while the ramps provide practical access for loading and unloading.
Combined with a switch to MPS pallet wrap, the customer has been able to streamline its pallet wrapping process while reducing its ongoing consumable costs.
Pallet Wrapping Solutions for Australian Distribution Centres
MPS Packaging Australia supplies, installs and supports pallet wrapping machines for warehouses, manufacturers and distribution centres throughout Australia.
Rather than looking at the pallet wrapper in isolation, we can assess the complete application – including pallet dimensions, weights, daily wrapping volumes, loading methods, stretch film consumption and the way pallets move through the warehouse.
Options can include powered pre-stretch, integrated weighing scales, loading ramps, extended turntables, low-profile turntables, automatic film attachment and cutting, remote controls and specialised pallet wrapping programs.
Whether you are wrapping a handful of pallets each day or operating a high-volume distribution centre, the right combination of pallet wrapper and stretch film can significantly reduce wrapping costs while improving consistency and load stability.
Talk to MPSpack about a pallet wrapping solution designed around your warehouse, your pallets and your actual wrapping volumes.
