In the past year, we have had two customers shift from shrink wrap to overwrap for their candy boxes.  In one case, it was to achieve costs savings in wrapping material. This customer is now looking at the energy savings that accompany getting rid of a shrink tunnel. Oddly though, the energy savings seem less important than the upscale look of their overwrap packaging  which they find more attractive than the shrink wrap.

What is the difference in the two processes?  Shrink wrap uses polyethylene film which is fitted around a package loosely, crimp-sealed around the edges and the excess cut off. It is then shrunk 20% in a heat tunnel to fit the package. The excess film that was cut off is sometimes recycled.

In contrast, there is no excess film with overwrap. The tuck and fold is neat to the package with no windows in the wrap. Heat is used for spot welding of the long seam and the tuck and fold.  Overwrap uses polypropylene film which is less expensive pound for pound than polyethylene of the same gauge. Because polypropylene film is crisper, you can fold it like paper and achieve that high end gift wrapped look. Because it is not shrunk, you can use registered film and have artwork on it.

We had one customer who achieved a 3 month payback on his switch to a high-end registered polypropylene laminate overwrap on a bundle rather than a shrink wrapped box with smaller boxes inside. He had additional savings in corrugated box costs, since his packages were smaller without the box.

So when do we recommend you use shrink wrap? Use it for ultra- low-volume runs where the cost to set up or changeover is too high. Use it for oddly shaped packages that are not suitable for a tuck and fold wrap/ gift wrap. If you want your package to be neat, and have a high end appeal, look at overwrapping it. Package can offer some low volume overwrap solutions.