Wrapping it Better
The Challenge:
A customer in British Columbia was using approximately 480 rolls of machine film annually to package their products. Inefficiencies in their packaging process were causing significant financial and operational setbacks.
Our Approach:
Addressing these issues involved a two-step approach:
- Expert Evaluation: An expert review was conducted to assess the existing packaging machinery, products, and techniques.
- Cut & Weigh Procedure: This crucial evaluation step compared the machinery’s current product use against optimal package wrapping requirements, and highlighted several inefficiencies:
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- One machine was found to be underperforming, by not adequately stretching the film and using excessive quantities of product.
- A second machine was applying 32 rotations of 50-gauge film per package, which far exceeded the packaging requirement and resulted in excess material use and unnecessary additional operational time.
The Solution:
To increase efficiency and reduce the identified material waste, we introduced the following solution:
- Equipment Upgrade: The underperforming machine was replaced with a new unit to ensure the proper film stretch capacity could be achieved.
- Optimization of Film Usage: We transitioned the second machine to an 80-gauge high-performance hybrid film, reducing the number of rotations needed per package. This not only reduced film costs but also reduced cycle time, labour costs and machine wear.
Results:
Implementing this solution resulted in impressive cost savings for the customer, including:
- Material Cost Reduction: The optimization of film usage resulted in annual savings of over $8,000 on film alone.
- Labour Cost Reduction: Enhanced machine efficiency reduced the time employees spent waiting for processes to complete, saving thousands in labour costs annually.
Bunzl Industrial Packaging takes pride in delivering customized, knowledge-driven solutions that not only solve immediate issues but also optimize long-term operational efficiency. Our hands-on approach ensures we understand and effectively address diverse business challenges and specific customer objectives.