Case Study: Streamlining Pallet Wrapping for a Distribution Specialist
Background
Our customer, a leading warehousing and distribution specialist, was facing significant challenges with their pallet wrapping process. Their existing machines were outdated, leading to frequent breakdowns, excessive plastic usage, and high operational costs. They needed a modern, efficient solution that would minimise downtime, improve packaging quality, and reduce costs.
Challenges
- Inefficient equipment - Operations were being delayed due to pallet wrapping machines that no longer functioned properly, requiring costly repairs.
- High plastic usage - The existing pallet wrapping process was using more plastic than necessary, increasing costs and contributing to waste.
- Inconsistent wrapping quality - The old machines were unable to consistently stabilise pallets, leading to issues with loads during transport.
Our Solution
Optimus Pallet Wrapping Machines and High-Yield Films
To address these challenges, we proposed replacing the outdated machines with Optimus pallet wrapping machines. These machines are designed with the latest technology, offering superior efficiency and cost savings.
Additionally, we recommended using Optimus high-yield pallet wrap films to further reduce plastic usage and improve load stability.
Key Benefits
Features of Optimus Wrapper Machines
- Advanced Pre-Stretch Technology - The supplied wrapper machines are equipped with a 250% pre-stretch carriage system (PPS models), ensuring that each metre of film is used to its maximum potential. This reduces the amount of plastic needed per pallet, resulting in significant savings.
- Programmable settings for different loads - The machines allow for programmable wrapping cycles, ensuring that different pallet types are wrapped consistently and securely.
- Minimised downtime - The ability to use up to 20kg rolls reduces the frequency of reloading, improving productivity in the packing area.
- Durable and reliable - The machines are manufactured using reputable European parts that are readily available in the UK, ensuring quick access to spare parts and reducing downtime.
- Warranty and support - Each machine comes with a 12-month warranty, and customers have the option to add Wrapper Machine Maintenance Packages for ongoing support and regular servicing.
Cost and Environmental Impact Reduction
By switching to Optimus machines and using high-performance films, the company was able to:
- Reduce plastic usage - Optimus high-yield pallet wrap films allow wrapping more pallets per roll, reducing overall plastic consumption and lowering the environmental impact.
- Reduce costs - The reduction in plastic usage, coupled with improved machine efficiency, resulted in substantial annual cost savings. This saving more than justified the investment in new machines.
- Minimise waste - The decrease in plastic waste also contributed to the company’s sustainability goals.
Optimised Wrapping Efficiency
With the new Optimus machines, the company saw immediate improvements in their wrapping process:
- Improved load stability - The consistent pre-stretch and programmable settings ensured that all pallets were wrapped securely, reducing the risk of load damage during transit.
- Increased productivity - By eliminating the downtime associated with reloading and maintenance, the company was able to significantly increase the number of pallets wrapped per day.
- Next-day delivery for critical support - Bonus Trading provided next-day delivery for all necessary parts and films, ensuring that the customer’s operations ran smoothly with minimal disruption.
Maintenance and Ongoing Support
To ensure long-term performance, Bonus Trading offered our Gold Maintenance Package, which includes:
- 6-monthly site visits - Regular inspections and servicing every 6 months, to keep wrappers in optimal condition.
- Discounted spare parts - Reduced costs on any necessary repairs or replacements.
- Visual checks and preventative maintenance - Checks on all key machine components, ensuring continued reliability and performance.
Results
Enhanced Efficiency and Cost Savings
By partnering with Bonus Trading, the warehousing and distribution specialist experienced the following improvements:
- 41% reduction in plastic usage - The use of high-yield films drastically cut plastic waste, supporting both cost-saving and sustainability initiatives.
- £4,509 annual savings - The combination of reduced plastic consumption and fewer machine breakdowns resulted in substantial cost savings.
- Increased pallet throughput - The company significantly increased its daily pallet-wrapping capacity due to the efficiency of the new machines.
- Enhanced sustainability - The reduction in plastic waste and overall environmental impact aligned with the company’s sustainability goals, improving their eco-friendly credentials.
Customer Comments
“
A total game changer!
After research of our needs and providing comparisons, we ordered our new Optimus Pallet Wrapper from Bonus Trading. It has been a total game changer. Pallet wrapping used to be tedious and time consuming for our team. The pallet wrapping machine has wholly transformed that process. We noticed an immediate improvement in the efficiency and quality of our wrapped pallets.
The installation process was handled professionally, making sure everything was working perfectly. They walked us through all the features, which made a massive difference in getting our operators comfortable with it immediately.
It stands out as sturdy and durable, you can tell it’s built to last. We’ve been running it nonstop during busy periods, and it hasn’t let us down once. What used to take hours now only takes a fraction of the time, and the wraps are always secure and consistent.
Bonus Trading supplies us with the most suitable wrap film to achieve the best results. It’s been much more cost-effective than I expected because we’re using less film but still getting perfectly wrapped pallets every time.
I’m really happy and would highly recommend. It’s reliable, easy to use, and has made a massive difference in our daily operations.”
MANAGER - DISTRIBUTION WAREHOUSE
Conclusion
Bonus Trading provided a tailored solution that addressed the customer’s challenges with outdated equipment, high plastic usage, and inefficient processes.
By implementing Optimus pallet wrapping machines and high-yield pallet wrap stretch films, the company has achieved significant cost savings, improved load stability, and reduced environmental impact.
Interested in improving your productivity?
Are you interested in reducing your plastic usage and improving your wrapping efficiency?
To learn more about our pallet wrapping solutions, how we can support your business, or to book an on-site demo - contact us today →
Call 08000 540 100 or email sales@bonustrading.co.uk
