Usually we are providing an overwrapper for the end of the primary packaging line. Recently we were asked to provide an overwrapper for both end of the primary packaging line but also to replace the intermediate box that is used at the start of  secondary packaging.

Primary packaging is defined as that which the customer takes home. Secondary packaging is that which gets it to the store for customers to purchase. Waste can occur anywhere along this distribution stream.

intermediate cardboard packaging box

In this case, we were looking at waste reduction in the secondary packaging. The clear savings was in weight reduction by removing the cardboard and replacing it with film, which weighs less and takes up less space. But waste reduction extends often to reducing the corrugated carton size which further extends the savings in transportation weight and material used.

The interesting things happen in the testing though. What happens when we get ready to test product that has been wrapped once already is that we need to determine a film for bundling that has a significantly different melt point than the underlying film. Otherwise we can find the film for the primary package sticking to the film for the bundling.

In this case the SKUs included product that was bundled for sale in lots of two, three or four and then bundled for distribution in lots of twelve or twenty four.

overwrapped bundles replace cardboard boxes for shipment to retailer

Not only do we find ourselves unwrapping the product as part of our in-house testing of the machine, but we are now testing for different melt points and adhesion of the bundle wrap to the SKU wrap.

Due to limited amount of product for testing and the number of bundle sizes to testff, we find ourselves unwrapping as much as the machine wraps, so that we can rewrap in a different configuration. We are very busy at the end of the line and then running back and forth to put it in the conveyor at the front of the machine. The run off can make us look like Lucille Ball trying to outpace the flow of product.

Ultimately the savings occur at several points in the packaging and shipping process.

• reduction in cardboard which costs more than film
• reduction in shipping weight from manufacturer to wholesaler or retailer
• reduction in corrugate use to hold the smaller bundles that contain the same amount of product as before
• reduction in waste in intermediate packaging at the point the product goes on the shelf at the retailer

At Package Machinery, we love projects like this that allow us to help our customers create savings through their distribution stream. Let us know how we can help you. email sales@packagemachinery.com for more info.