Wrapping, shrink wrapping or best of all stretch hooding?
Packaging technologies compared:
Load securing is crucial
In the chemicals industry, the efficient packaging of palletized goods is a crucial competitive factor for many businesses. The issues involved relate to transport security, the display impact made by the packaged goods and protection against the elements when products are stored outdoors. However, process efficiency and cost reductions – i.e. energy and materials consumption – are other vital factors. As, too, is output: the number of pallets that a company is able to package in a given time. A comparison has shown that the stretch hood process is particularly efficient. One leading PVC raw materials manufacturer, Vinnolit GmbH & Co. KG, is therefore replacing its shrink hood system with a high-performance machine from the BEUMER stretch hood series.
Fig. 1:
Many companies are using the stretch hood process
to reduce transport damage and meet more exacting logistical demands.
In a whole range of industries, palletization and packaging play an important role in ensuring that goods reach customers and dealers in the best possible condition. Raw materials destined for the chemicals industry number among the products that need special protection during transport and storage, for example against the effects of the weather and humidity. Manufacturers can choose between a number of different packaging solutions. For them, the aim is to use the most economical and most ecologically sustainable solution. Currently, there are three methods for packaging pallets on the market: the stretch wrapping, shrink hood, and stretch hood processes.
Fig. 2:
The stretch hood process permits the reliable protection of palletized loads.
This includes waterproof pallet packaging on five sides.
The stretch wrapping process is particularly popular
Because initial investments in stretch wrapping machines are significantly lower than in the case of shrink or stretch hood machines, this is the favored packaging method for many companies from a range of industries. In Europe alone, it is estimated that 1.4 million tonnes of stretch wrapping film is used for palletization purposes every year. Because the process uses a very large amount of material, operators have to change the film rolls at regular intervals. It is therefore suitable for low-output production operations.
Fig. 3:
Left to right: Diagrammatic overview of the shrink hood process,
stretch wrapping process and stretch hood process.
As its name implies, stretch film is elastic. As a result, it gives the palletized goods stability when they are packaged. However, this method only weakly tensions the load in the vertical direction. And it is precisely this vertical tension that holds the load in place when subjected to transport stresses. In order to protect products against the effects of the weather and humidity, the user must secure the load from above using additional films. Because the films overlap, the packaged goods are not shown off to best effect and any barcodes applied below the film are difficult to read. And because the film is wrapped around the goods, it cannot be printed. Another disadvantage lies in the fact that, due to its adhesive properties, the film attracts dust particles, with the result that the pallets become dusty after an extended period of storage. It also provides no protection against theft: unauthorized persons can take goods from the pallet without destroying the film.
Fig. 4:
The BEUMER high-performance stretch hood packaging system
at work at the Vinnolit site.
Efficient packaging with shrink film
In the shrink wrapping process, the film is manufactured in tubular form in blow head extruders with tubular dies and is then further processed to create hoods or cut to produce flat film. During the shrinking process, the film is heated by hot air up to the softening point. During this operation, it snaps back to fit around the precise contours of the palletized goods and, as it cools, develops tension that helps to secure the load. The packaging system uses either electricity or gas to generate the heat required for the shrink wrapping process. The film can be guided over the base of the pallet. This approach not only provides a high level of load security. Even when stored in the open air, the goods are safely protected against environmental influences such as snow, rain, UV radiation, dust and insects. However, because the film becomes opaque as a result of the shrink wrapping process, it is difficult to identify the packaged products or any barcodes printed on them. And there are other drawbacks: Polyethylene (PE) bags may fuse with the plastic in the packaging film and the heat effect increases the risk of fire. And it takes between two and four kilowatts per pallet to generate the heat required for the process – an energy requirement that is higher than that involved in other packaging processes.
Fig. 5:
Depending on stack height, Vinnolit uses
four different thicknesses of PE film.
Stretch hood technique for increased transport security
Stretch film adapts to fit the stacks of products for packaging. The film is highly stretchable and is therefore able to secure the material as it contracts. This process therefore provides a high level of load security. The film also does not stick to the product. The pallet can be packaged in a way that is suitable for high-bay warehouses or with understretch. The smooth, continuous surface of the film permits a clear view of the packaged goods. This results in an excellent display impact at the point of sale. Barcodes on the goods are also recognized without errors. The employed film can be recycled. In the stretch hood process, it is also not heated. This significantly reduces the risk of fire, increases operating safety and therefore also reduces insurance premiums. Because less film and energy are needed, the environmental impact is also reduced. When a cover film is placed over the top of the pallet, this solution also protects the goods against external influences from all six sides.
Fig. 6:
The highly flexible properties of the film enable it to be drawn
over the entire pallet load before it snaps together again for the understretch.
A comparison of the packaging processes
BEUMER's product portfolio includes innovative equipment and systems for all these packaging processes. Because, alongside load security, protection against external influences is another decisive factor for most companies when choosing the most suitable packaging process, BEUMER's experts have compared the shrink hood and stretch hood processes – and have concluded that the stretch hood approach offers clear cost advantages. To do this, they took a palletized stack of height 1,630 millimeters as an example. Systems that package palletized goods using the shrink wrapping approach are able to process between 35 and 70 pallets per hour. The thickness of the film is between 120 and 180 micrometers. At between 100 and 120 pallets per hour, the stretch hood process achieves almost double the output. The processed film is also thinner, at between 70 and 140 micrometers. What is more, because the film is stretchable, this process also consumes less material.
In 2014, the market price for shrink wrapping film was 1.70 euros per kilogram. The packaging costs for one film hood were approximately 1.02 euros. Given an output of 300,000 pallets per year, the film cost would be approximately 306,000 euros. The current market price for the film used in the stretch hood process is a little more expensive at 1.90 euros per kilogram. However, the cost of the material required to produce a film hood is only 57 cents. Given the same number pallets for processing every year, the cost difference of approximately 159,000 euros is considerable. Users can make savings of approximately 52 percent.
There is also a difference in the energy requirements of the two systems. Gas consumption in the case of shrink wrapping amounts to some two kilowatt hours per pallet. The energy requirement in order to produce a stretch hood amounts to six cents. Given our theoretical output of 300,000 pallets per year, the cost to the user is therefore approximately 18,000 euros. Because the stretch hood system works without gas and the cost of the electricity consumed by the two processes is practically identical, users of the stretch hood solution also save on these costs. Energy-saving motors and a lower compressed air requirement go even further toward ensuring a harmonious energy equation. In the most recent machines to be added to the BEUMER stretch hood series, it has been possible to reduce the compressed air requirement by 80% compared to earlier models. The use of extremely thin films and the prevention of defective hoods also help protect the environment.
Repair and maintenance costs for the equipment used in the shrink wrapping process vary between 2,000 and 8,000 euros per year, in particular in the case of older machines. An amount of 4,000 euros has been assumed for the purposes of this calculation. The observed average costs in the stretch hood process are between 1,000 and 3,000 euros per year. If we assume an average value of 2,000 euros, then the user saves 2,000 euros for maintenance activities. Here again, users of the stretch hood process also benefit from a considerably lower financial burden over the year.
Fig. 7:
This high-performance packaging system is based on a
variable machine concept that can be adapted individually
to the project situation and application.
More efficient bag packaging using the stretch hood process
Vinnolit GmbH &Co, which has its head office in Ismaning, Germany, has also opted for stretch hood technology. In its factory in Gendorf, the company, which is Europe's leading raw materials manufacturer and a global technology leader for specialty PVC products, fills its PVC powder into paper bags and then stacks these on pallets. "These pallets are of different heights. Depending on the bulk density, some bags contain 35 liters and others 52," explains Reinhard Birnkammer, Head of SCM Polymer at Vinnolit. To ensure that the load units are stable at all times, the stacks of bags are packaged using films of differing thicknesses – the higher the stack, the thicker the film. The company previously used a shrink wrapping system. However, this was beginning to show its age and was no longer able to satisfy the quality requirements. "Not only did it take 20 minutes to change the film roll, but the choice of film was also very limited," recalls Birnkammer. And the requirements placed on load security are growing all the time. The paper bags also possess valves which, in the past, frequently ripped holes in the film.
It was clear to the PVC manufacturer that the time for a new packaging system had arrived. "First of all, we thought about the stretch wrapping process," says Birnkammer. But then the company discovered the machines in the BEUMER stretch hood series. This equipment range benefits from a variable machine concept. It can be adapted individually to all project situations and applications. The machine controller detects the different stack heights automatically. Users are flexible in their choice of film. The PE stretch film hoods that are used have a high breaking strength and piercing resistance. The required elongation values and the tensioning forces acting along two axes are perfectly harmonized for every product and all operating conditions. The low energy consumption and the possibility of using recyclable packaging films were further factors in favor of this solution. "As a result, the system constitutes an economical, environmentally responsible product packaging variant," explains Birnkammer.
Photos: BEUMER Group GmbH & Co. KG
BEUMER Group is an international manufacturing leader in intralogistics in the fields of conveying, loading, palletising, packaging, sortation and distribution technology. Together with Crisplant a/s and Enexco Teknologies India Limited, BEUMER Group employed some 4,000 people in 2014. The group generated an annual turnover of approximately 680 million euros. With its subsidiaries and sales agencies, BEUMER Group is present in many industries worldwide.
BEUMER: Load Securing is Crucial
Wrapping, shrink wrapping or best of all stretch hooding?
Packaging technologies compared:
Load securing is crucial
In the chemicals industry, the efficient packaging of palletized goods is a crucial competitive factor for many businesses. The issues involved relate to transport security, the display impact made by the packaged goods and protection against the elements when products are stored outdoors. However, process efficiency and cost reductions – i.e. energy and materials consumption – are other vital factors. As, too, is output: the number of pallets that a company is able to package in a given time. A comparison has shown that the stretch hood process is particularly efficient. One leading PVC raw materials manufacturer, Vinnolit GmbH & Co. KG, is therefore replacing its shrink hood system with a high-performance machine from the BEUMER stretch hood series.
Fig. 1:
Many companies are using the stretch hood process
to reduce transport damage and meet more exacting logistical demands.
In a whole range of industries, palletization and packaging play an important role in ensuring that goods reach customers and dealers in the best possible condition. Raw materials destined for the chemicals industry number among the products that need special protection during transport and storage, for example against the effects of the weather and humidity. Manufacturers can choose between a number of different packaging solutions. For them, the aim is to use the most economical and most ecologically sustainable solution. Currently, there are three methods for packaging pallets on the market: the stretch wrapping, shrink hood, and stretch hood processes.
Fig. 2:
The stretch hood process permits the reliable protection of palletized loads.
This includes waterproof pallet packaging on five sides.
The stretch wrapping process is particularly popular
Because initial investments in stretch wrapping machines are significantly lower than in the case of shrink or stretch hood machines, this is the favored packaging method for many companies from a range of industries. In Europe alone, it is estimated that 1.4 million tonnes of stretch wrapping film is used for palletization purposes every year. Because the process uses a very large amount of material, operators have to change the film rolls at regular intervals. It is therefore suitable for low-output production operations.
Fig. 3:
Left to right: Diagrammatic overview of the shrink hood process,
stretch wrapping process and stretch hood process.
As its name implies, stretch film is elastic. As a result, it gives the palletized goods stability when they are packaged. However, this method only weakly tensions the load in the vertical direction. And it is precisely this vertical tension that holds the load in place when subjected to transport stresses. In order to protect products against the effects of the weather and humidity, the user must secure the load from above using additional films. Because the films overlap, the packaged goods are not shown off to best effect and any barcodes applied below the film are difficult to read. And because the film is wrapped around the goods, it cannot be printed. Another disadvantage lies in the fact that, due to its adhesive properties, the film attracts dust particles, with the result that the pallets become dusty after an extended period of storage. It also provides no protection against theft: unauthorized persons can take goods from the pallet without destroying the film.
Fig. 4:
The BEUMER high-performance stretch hood packaging system
at work at the Vinnolit site.
Efficient packaging with shrink film
In the shrink wrapping process, the film is manufactured in tubular form in blow head extruders with tubular dies and is then further processed to create hoods or cut to produce flat film. During the shrinking process, the film is heated by hot air up to the softening point. During this operation, it snaps back to fit around the precise contours of the palletized goods and, as it cools, develops tension that helps to secure the load. The packaging system uses either electricity or gas to generate the heat required for the shrink wrapping process. The film can be guided over the base of the pallet. This approach not only provides a high level of load security. Even when stored in the open air, the goods are safely protected against environmental influences such as snow, rain, UV radiation, dust and insects. However, because the film becomes opaque as a result of the shrink wrapping process, it is difficult to identify the packaged products or any barcodes printed on them. And there are other drawbacks: Polyethylene (PE) bags may fuse with the plastic in the packaging film and the heat effect increases the risk of fire. And it takes between two and four kilowatts per pallet to generate the heat required for the process – an energy requirement that is higher than that involved in other packaging processes.
Fig. 5:
Depending on stack height, Vinnolit uses
four different thicknesses of PE film.
Stretch hood technique for increased transport security
Stretch film adapts to fit the stacks of products for packaging. The film is highly stretchable and is therefore able to secure the material as it contracts. This process therefore provides a high level of load security. The film also does not stick to the product. The pallet can be packaged in a way that is suitable for high-bay warehouses or with understretch. The smooth, continuous surface of the film permits a clear view of the packaged goods. This results in an excellent display impact at the point of sale. Barcodes on the goods are also recognized without errors. The employed film can be recycled. In the stretch hood process, it is also not heated. This significantly reduces the risk of fire, increases operating safety and therefore also reduces insurance premiums. Because less film and energy are needed, the environmental impact is also reduced. When a cover film is placed over the top of the pallet, this solution also protects the goods against external influences from all six sides.
Fig. 6:
The highly flexible properties of the film enable it to be drawn
over the entire pallet load before it snaps together again for the understretch.
A comparison of the packaging processes
BEUMER's product portfolio includes innovative equipment and systems for all these packaging processes. Because, alongside load security, protection against external influences is another decisive factor for most companies when choosing the most suitable packaging process, BEUMER's experts have compared the shrink hood and stretch hood processes – and have concluded that the stretch hood approach offers clear cost advantages. To do this, they took a palletized stack of height 1,630 millimeters as an example. Systems that package palletized goods using the shrink wrapping approach are able to process between 35 and 70 pallets per hour. The thickness of the film is between 120 and 180 micrometers. At between 100 and 120 pallets per hour, the stretch hood process achieves almost double the output. The processed film is also thinner, at between 70 and 140 micrometers. What is more, because the film is stretchable, this process also consumes less material.
In 2014, the market price for shrink wrapping film was 1.70 euros per kilogram. The packaging costs for one film hood were approximately 1.02 euros. Given an output of 300,000 pallets per year, the film cost would be approximately 306,000 euros. The current market price for the film used in the stretch hood process is a little more expensive at 1.90 euros per kilogram. However, the cost of the material required to produce a film hood is only 57 cents. Given the same number pallets for processing every year, the cost difference of approximately 159,000 euros is considerable. Users can make savings of approximately 52 percent.
There is also a difference in the energy requirements of the two systems. Gas consumption in the case of shrink wrapping amounts to some two kilowatt hours per pallet. The energy requirement in order to produce a stretch hood amounts to six cents. Given our theoretical output of 300,000 pallets per year, the cost to the user is therefore approximately 18,000 euros. Because the stretch hood system works without gas and the cost of the electricity consumed by the two processes is practically identical, users of the stretch hood solution also save on these costs. Energy-saving motors and a lower compressed air requirement go even further toward ensuring a harmonious energy equation. In the most recent machines to be added to the BEUMER stretch hood series, it has been possible to reduce the compressed air requirement by 80% compared to earlier models. The use of extremely thin films and the prevention of defective hoods also help protect the environment.
Repair and maintenance costs for the equipment used in the shrink wrapping process vary between 2,000 and 8,000 euros per year, in particular in the case of older machines. An amount of 4,000 euros has been assumed for the purposes of this calculation. The observed average costs in the stretch hood process are between 1,000 and 3,000 euros per year. If we assume an average value of 2,000 euros, then the user saves 2,000 euros for maintenance activities. Here again, users of the stretch hood process also benefit from a considerably lower financial burden over the year.
Fig. 7:
This high-performance packaging system is based on a
variable machine concept that can be adapted individually
to the project situation and application.
More efficient bag packaging using the stretch hood process
Vinnolit GmbH &Co, which has its head office in Ismaning, Germany, has also opted for stretch hood technology. In its factory in Gendorf, the company, which is Europe's leading raw materials manufacturer and a global technology leader for specialty PVC products, fills its PVC powder into paper bags and then stacks these on pallets. "These pallets are of different heights. Depending on the bulk density, some bags contain 35 liters and others 52," explains Reinhard Birnkammer, Head of SCM Polymer at Vinnolit. To ensure that the load units are stable at all times, the stacks of bags are packaged using films of differing thicknesses – the higher the stack, the thicker the film. The company previously used a shrink wrapping system. However, this was beginning to show its age and was no longer able to satisfy the quality requirements. "Not only did it take 20 minutes to change the film roll, but the choice of film was also very limited," recalls Birnkammer. And the requirements placed on load security are growing all the time. The paper bags also possess valves which, in the past, frequently ripped holes in the film.
It was clear to the PVC manufacturer that the time for a new packaging system had arrived. "First of all, we thought about the stretch wrapping process," says Birnkammer. But then the company discovered the machines in the BEUMER stretch hood series. This equipment range benefits from a variable machine concept. It can be adapted individually to all project situations and applications. The machine controller detects the different stack heights automatically. Users are flexible in their choice of film. The PE stretch film hoods that are used have a high breaking strength and piercing resistance. The required elongation values and the tensioning forces acting along two axes are perfectly harmonized for every product and all operating conditions. The low energy consumption and the possibility of using recyclable packaging films were further factors in favor of this solution. "As a result, the system constitutes an economical, environmentally responsible product packaging variant," explains Birnkammer.
Photos: BEUMER Group GmbH & Co. KG
BEUMER Group is an international manufacturing leader in intralogistics in the fields of conveying, loading, palletising, packaging, sortation and distribution technology. Together with Crisplant a/s and Enexco Teknologies India Limited, BEUMER Group employed some 4,000 people in 2014. The group generated an annual turnover of approximately 680 million euros. With its subsidiaries and sales agencies, BEUMER Group is present in many industries worldwide.
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