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The Right Medicine: Pallet-Wrapping Diagnosis Means Healthier Bottom Line for Pharmaceutical Company

As part of a cost-cutting and quality-assurance initiative, a pharmaceutical company called us in to evaluate the methods and materials that it was using to secure their product on pallets for shipment via tractor trailer. In addition to the evaluation, the customer also wanted us to help establish quality criteria/testing related to this packaging function that would allow them to periodically measure the consistency and integrity of the palletized loads.

Current process:

The customer was using semi-automatic pallet wrappers to wrap the palletized loads with conventional 80-gauge stretch film.

Action steps:

• We used our DSLLC stretch-test kit to measure the percentage that the current film was being stretched as it was run through the wrapper and applied to the load.

  Note: Stretch percentage is important to ensure that you are getting the most out of the film. It is obviously more cost-efficient to stretch the film to its practical limit, but it is also important to note that stretch film gets stronger when it is stretched properly and its “memory” is enhanced similar to that of a rubber band.

• We used a Force-to-Load gauge to measure the force that the film was placing on the load after it was wrapped.
• We cut the film off of the load and weighed it to establish the amount of film being used per load.
• Finally, we wrapped the same load with one of our advanced-formulation films (thinner/stronger). We performed the same tests as above and recorded the measurements.

Results:

• We were able to use less of the new, advanced-formulation film while achieving a better force-to-load measurement. The customer is realizing significant material savings and increased load integrity.
• The customer now has established measurable standards for load containment that can be integrated into their quality assurance program.
• We agreed to perform quarterly scheduled maintenance to include the equipment as well as the film tests to ensure the consistency of this packaging function and provide documentation for their quality program.
• The customer is able to promote this as an additional quality initiative and service to their customers.

Lesson:
Significant savings and efficiencies are most often achieved by an examination of both the methods and materials involved in the process. Customers like this that have involved us in the process have realized savings well beyond the reach of a purchasing department that is simply soliciting quotes on current materials.