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Today’s Leading Stretch Film LLDP Manufacturers

Posted on August 27, 2024 by Richard Taszarek
Table Of Contents
  1. Blown Stretch Film
  2. Cast Stretch Wrap
  3. Coextrusion Technology
  4. Major Extrusion Companies in Europe Today
  5. North America's Extrusion Landscape
  6. Extrusion in the East
  7. The Future of Extrusion

When we purchase our packaging materials, we often do not consider the vast amounts of effort and machinery that go into producing these products, which are so intrinsic to our packaging success. So, what machinery is involved in making one of our most commonly used commodities in the packaging industry: stretch wrap? Plastic extrusion is a high-volume manufacturing process in which raw plastic, such as linear low-density polyethene, is melted and formed into a continuous profile. An extruder is the equipment used to change solid polymers into molten polymers. Today, the marketplace for LLDPE stretch wrap is extremely fierce, with many processors’ profits being within a fraction of one another per lb. The processors that are experiencing growth are the ones who choose to invest in the new highly layered films created using multiple extruders.

Blown Stretch Film

Two extrusion methods are currently used to produce the traditional mono-extrusion stretch wrap of the past. “Blown stretch film” accounts for 30-35% of stretch wrap produced and is typically used for commodity hand wrapping. Blown extrusion uses melted plastic resin extracted into a closed circular bubble with air blown through it to cool the resin. This process involves a circular die, where the molten resin is inflated with air to form a bubble of molten plastic before being chilled and collapsed into a thin film. Airflow is blown on the outside of the bubble, which chills the film as it pulls upward. This creates a tube of thin film which can be wound into rolls for use. Blown stretch film is known for its higher durability and is suitable for wrapping sharp-edged products and heavier loads.

Cast Stretch Wrap

The most popular type of LLDPE stretch wrap is “cast stretch film”,; which accounts for 60-75% of all stretch wrap produced and is used mainly for machine wrapping. Cast extrusion production, though more costly in the initial machinery set-up, is cheaper in the long run when compared to blown extrusion. Cast stretch film is known for its high transparency, which increases product visibility and aids in inspecting the integrity of packaging. Cast extrusion differs from “blown” by using rollers to cool the plastic resin. One of the unique characteristics of cast stretch film is its superior adhesion and cost-effectiveness for smaller weights. Once the resin is extracted from the extruder, it is cooled and solidified on cooling rolls. When the film reaches the end of the cooling rolls, it is trimmed and can be rolled directly onto a material roll for resale.

Coextrusion Technology

In order for processors to enjoy success in today’s market, multi-layered stretch wrap needs to be produced using a coextrusion machine. Coextrusion is the process of pressing two or more materials through the same die to produce a single piece. These systems are designed to produce multi-layer film and have two or more extruders feeding a common die assembly. Coextrusion technology improves the wrapping process by enhancing efficiency, reducing costs, and minimizing environmental impact.

The number of extruders depends on the different materials comprising the coextruded film. For instance, a three-layer coextrusion consisting of a recycled or barrier material core and two outer layers of the same resin requires only two extruders. In contrast, a five-layer coextrusion comprised of a top layer of LLDPE, a tie-layer resin, a barrier resin, another tie-layer and an EVA resin layer would require four or five extruders. A typical three- to five-layer cast film extruder costs up to €700,000.

Since 1982, the market has been moving away from traditional mono-film, and today, manufacturers typically produce 7-layered films that can stretch 250%+. However, some European companies are creating a future-forward 34-layered film that can stretch up to 300%+ and is reigning in the stretch wrap production industry. The multi-layered films produced by coextrusion also offer superior tear resistance, ensuring reliable performance and stability under load.

Major Extrusion Companies in Europe Today

The growing trend of multi-layer LLDPE has led to the growth of dozens of nanolayers, which give the material a “plywood” structure, enhancing the stretch wrap’s tear and puncture resistance. This highly elastic thin plapolyetheneade from polyethene (PE) resins is used for pallet wrapping, bundling, securing, and packaging goods by stretching and compacting, tightly wrapping them together. So, what constitutes a nanolayer? A nanometer is 1/1000 of a micron. There are 25,400 nanometers in one mil. In a cast film, layers can be as thin as 100 nanometers. The elastic recovery properties of these films ensure that items remain tightly bound and enable improved cling performance for the safe transportation of goods. Then, when this film is stretched above 300%, you arrive at layer thicknesses of less than 25 nanometers (0.0009 mil).

Dutch Flexible Packaging

The country making the most giant waves in the extrusion industry is Holland, which has been utilising nanolayer extrusion technology since 2009. This technology helps keep items tightly bound during transportation due to its highly elastic recovery nature. In one of their leading manufacture’s most recent film structures, 22 of the 27 layers are nano in a “2 x 11” structure, allowing more expensive, higher-performance sub-skin layers to sandwich a thicker core. Of course, the company’s director is extremely tight-lipped regarding the formulation and layer configuration, though happily states that the company is now well on the way to producing its third nanolayer extrusion line with more than 50 layers.

Eastern Europe

The European factories have collaborated with extrusion innovators Windmoller & Holscher KG and Cloeren since 2014. This new technology helps in securing pallet loads by providing a tighter and more stable wrap. They together are producing a 33-layered stretch wrap with a thickness measuring as little as 8 microns. This material is also suitable for heavier loads, ensuring durability and strength. Cloeren delivered its specialist feedback and die technology, while Windmöller & Hölscher provided industry-leading processing and manufacturing expertise for the cast stretch machine. This material uses 50% less film to wrap products when compared to typical stretch wrap. This advanced material offers excellent value for money and improves the carbon footprint of those who adopt it.

United Kingdom

In the UK, companies are not yet stocking the brand-new nanolayered technology, though they are well on their way. The new multi-layered films offer unparalleled tear resistance, ensuring reliable performance and stability under load. Companies are investing in multi-layered extruders by technology giants such as Macchi, one of the leading extruder brands that have been trailblazing since 1961. They offer cast and blown stretch wrap with over 250% stretch. The Italian extruder brand Macchi can now supply stretch film up to 11 layers.

Macchi Timeline:

  • 1961 – Granted the patent for the first two-layer coextrusion die
  • 1980 – The expansion of Coextruder 3-layer
  • 2000 – Introduction of the Coex 5 layer & development of Coextruder 7 layer
  • 2009 – The world’s first Coextruder 9 layer with nanolayers

Brückner Service

Since 1970, stretch wrap producers in Britain have been manufacturing and distributing 100% recyclable LLDPE. The new multi-layered films have unique characteristics that enhance their performance and versatility in various packaging applications. In recent years, the major players have been upgrading their existing traditional 3-layered extruders to 5-layers with the help of extruder machine technology provided by Brückner Service. Two additional co-extruders with melt pipes, filter and adapter block, and a new die with die lip adjustment were installed, all utilising Brückner’s state-of-the-art technology. Along with the new co-extruders, a new thickness gauge was installed to make the machines highly efficient.

Since 2010, the distribution of higher layer capacity has been much larger throughout Europe. The under-utilised capacity is due to the installed capacity not being utilised because of patent rows.

North America’s Extrusion Landscape

In North America, there has been limited progression in the multi-layer stretch wrap industry due to huge patent rows, which have been ongoing since 2012. Stretch wrap technology giants have filed lawsuits against nine stretch film processers claiming violations against patents covering films with seven or more layers. In November 2015, an opposing leading extruder manufacturer had the Federal Court rule in their favour, though their competitor is currently appealing. With 0.5% of retail sales lost to damage in North America, progress must be made to manufacture multi-layered stretch wrap. Linear low-density polyethene is commonly used in North American stretch film production for pallet wrapping, bundling, and securing.

Though limited, there are signs of innovation in North America. A stretch wrap factory based in New Jersey, currently America’s biggest stretch film producer, has installed a nine-layer cast stretch machine imported from Austria. This expansion has caused their competitors to increase their growth plans, and there are now talks of major developments throughout the US stretch wrap industry. Market experts estimate these developments will contribute to the stretch film industry growing 4.5% by 2017.

Extrusion in the East

With Europe’s technology paving the way, the Far East has been doing all it can to keep up with the competition. However, though the stretch wrap may be produced in Asia, the technology is strictly German. Reifenhauser has supplied over 15 extruder lines across Asia since 2014, ranging from 5 layers upwards. These extruder lines are used to produce highly elastic thin plastic film made from polyethene (PE) resins, which is essential for pallet wrapping, bundling, securing, and packaging goods.

A prominent Malaysian stretch wrap distributor has taken inspiration from Europe’s innovation. It is currently the number one stretch wrap manufacturer in the Asia-Pacific region, producing an eye-watering capacity of 200,000 metric tonnes per year across its 16 production lines. The high transparency of the films produced enhances product visibility, aids in inspecting the integrity of packaging, and improves warehouse operations by identifying products.

They have collaborated with German technology authorities Reifenhauser to produce innovative stretch wraps in the East. Their latest nanolayer extruder manufactures a 22-layered cast film with a thickness reduced to 6 microns and is the first of its kind to be installed in the Asia Pacific region. These major players export 90% of their films globally, including to Scotland.

Indonesia is also taking steps in the Asia-Pacific stretch-wrap industry, though it only exports LLDP stretch film up to five layers. This is because they only utilise American extrusion technology, which, as we know, has been stalled since 2012 due to bitter legal battles. Their products range from 15 to 12 microns, but this is no comparison to the 6 microns their competitors can supply.

The Future of Extrusion

With stretch wrap continuing to be one of the fastest-evolving film markets, there is a lot of optimism for those working within the field as demand shows no signs of slowing down. The future films are expected to have enhanced elastic recovery properties, making them highly stretchable and tightly binding when wrapped around items, especially during transportation. In 2014, stretch film production was divided into two categories: 1,467.4 million lb (75.8%) consisted of multi-layer coextruded film, and 468.4 million lb. (24.2%) was monolayer film. These future films will keep items tightly bound, ensuring improved cling performance for the safe transportation of goods. With technology ever growing and the demand the way it is, the future sees the production of multi-layered stretch wrap and the extruders needed to create it continue increasing their market share.

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A Guide to Pallet Wrapping Machines and a Bit of History for Everyone

Posted on August 5, 2024 by Richard Taszarek

In the 1900s, the plastics industry boomed, and with that came a particular change in the way the packaging industry operated forever: stretch wrap. Today, this revolutionary product continues to be intrinsic to the success of the industrial packaging industry. Since its introduction, stretch wrapping has become the prevailing method of unitising products on pallets for safe shipment to their destinations. But what would stretch wrap be without the pallet wrapping machine? Like most of our most-loved products, we take technology for granted and often don’t think about their origins. Pallet wrapping machines are probably the most numerous pieces of packaging equipment in the industry. So, let’s look into the history and mechanics of this essential piece of wrapping machinery.

Before the invention of the pallet wrapping machine in the 1970s, companies had no choice but to load trucks with their products individually or use metal strapping or shrink bags to unitise loads. These practices were labour-intensive, expensive, and physically draining. Surely there had to be another way?

The first stretch wrapper came to fruition in 1973; Brothers Pat and Bill Lancaster unveiled the invention at the Packaging Machinery Manufacturer’s Trade Show. This machine showcased a way to unitise products on pallets by wrapping them in layers of plastic film. Not only was this a less labour-intensive method of palletisation, but it was also cheaper. Now, instead of taking many working hours to floor load a truck, a forklift driver could load an entire truck in less than 30 minutes. Typically, wrapping with steel strapping would take a long time to complete, whereas utilising a pallet wrapper would mean the load is secured in just over one minute. Not only could it wrap pallets more cheaply, but it was also mobile.

This was a well-thought-out solution to yesterday’s wrapping needs. Three of its features are still being used today: It’s mobile, has a rectangular turntable, and is a mechanical brake machine. Development in extruders and film technology means that the film is now only 500mm wide, so it must travel up and down the mast. The right machine stretch is crucial for securing and shipping palletised goods efficiently.

How do pallet wrappers work?

They have two or three motors: one/turns the turn table, two lifts the film carriage up and down the mast, and three stretch and lay the film onto the loaded pallet. (power stretch variety)

Pallet wrapping has been made more convenient by the use of machines. Pallet wrapping machines reduce the amount of time spent packing products and make businesses more productive. What’s more, less waste material is created due to inefficient human error. Pallet-wrapping machines protect your company’s load by wrapping multiple layers of film over it. Pallet wrap machines are known for their efficiency, reliability, and cost-saving benefits, making them an essential tool for any business. Pallets are loaded into position, and the turntable is rotated until the load is completely covered. There are many models to choose from, and there are three fundamental styles to consider: turntable, straddle, and robot.

  • A turntable stretch wrapper spins the load on a turntable while the film delivery system moves up and down the mast and dispenses the film around the pallet. Typically, these turntables spin around at up to 12 revolutions per minute. This type of wrapper can handle most wrapping needs. 8 out of 10 pallet wrappers sold are turntable systems. They are cheaper than using labour.
  • A straddle stretch wrapper works oppositely; the load remains static, and the film delivery system rotates and moves up and down to distribute the film. This type of machinery is used more often for light loads and unstable loads, which may fall over on a turntable when it starts to rotate. Because it is fed with a conveyor belt, its throughput is far higher than a stand-alone turn table. They do not require labour as they will wrap and move pallets unattended.
  • It has advantages where the environment is dirty or very cold; it keeps the main pallet wrapper out of harms away, suspended in the air.
  • The robot can go anywhere (wrap anything; it has all the sophisticated programs of the static turntable). Utilizing pallet wrapping machines eliminates the need to manually transport unwrapped pallets to the stationary pallet wrapper within the factory. Apart from moving the robot to the place of work, it wraps pallets unaided.

The three methods of wrapping pallets

  • Before purchasing a pallet wrapping machine, there are several factors to consider. Straddle stretch wrappers, with their rotating arm and supporting frame, require more floor space compared to turntable machines but offer high throughput. Additionally, straddle wrappers need to be securely anchored to the floor. On the other hand, turntable machines are more compact and convenient for businesses dealing with various load sizes or limited floor space.
  • When it comes to operation, semi-automatic pallet wrapping machines are recommended for companies wrapping low to high volumes. These machines offer a safe and efficient method where an operator simply needs to place the load on the machine, secure the film, and start the wrapping cycle. In contrast, automatic pallet-wrapping machines operate without any manual intervention. Pallets are automatically fed into the machine via a conveyor system while sensors calculate the optimal wrapping height for each load. The film is cut and secured before the conveyor belt releases the wrapped pallet for loading and repeats the cycle seamlessly.
  • The latest technology in wrapping pallets is the robot. It operates by going self-propelled around the pallet to apply the film. It can travel to where the load needs to be wrapped. The use of pallet wrapping machines eliminates the need to transport unwrapped pallets around the factory for static wrapping. Using a stretch wrapping machine enhances efficiency, ensures precise wrapping, and reduces costs significantly.

Types of pallet wrappers

Core Break Pallet Wrappers

Core break pallet wrappers are entry-level turntables machines; there are only two working motors, one to turn the turn table and the other to lift the film carriage up and down the mast. The load is placed on the turntable with the aid of a forklift or pallet truck. The film is attached, the turntable revolves, and the film is pulled off the roll. Once the cycle is complete, the operator cuts the film, and the load is removed. Minimal machine stretch is applied to the film with this type of machine, which is crucial for securing the load during shipping. A light sensor controls the assent height on all pallet wrappers.

Power Pre-Stretch pallet wrappers

Depending on the machine’s age, model, and make, they will stretch the film from 100% to 300%. The difference between the core break and power stretch pallet wrapper is that the latter has a 3rd motor in the film carriage head. It performs three functions: 1/pulls the film from the roll, 2/stretches the film, and 3/controls the lay-on tension of the film to the load. They have multi-functional control panels so that almost any loaded pallet can be wrapped. The best of these machines will turn one meter of film from the roll into four meters to wrap the pallet. Stretch wrap machines, including robotic pallet wrapping machines and entry-level semi-automatic stretch wrap machines, are known for their efficiency and versatility. The real savings start here at 250/300% stretch.

Cut and clamp semi-automatic Power stretch pallet wrapper

These are the ultimate technology in stand-alone turn table wrapping machines. All that the operative has to do is place the loaded pallet onto the turn table. Press the start switch on their handheld console and walk /drive away. The stretch film is then applied to the pallet; it then rotates to wrap the load and stops when it’s done. The film is cut, and an arm secures/pats the tail securely to the wrapped pallet.

The advantage of this type of pallet wrapper is that it can save the company time in the wrapping cycle. The average wrapping cycle by pump truck is one minute to load and one minute to unload. Then, one minute to wrap on the machine, ie 3 minutes. (em for further details)

The cut and clamp saving are on the loading, unloading and applying film to the load then cutting the film before moving the pallet away for despatch. Different types of pallet wrap machines, such as robotic pallet wrapping machines and automatic pallet wrap machines, offer benefits like increased production speed, ensuring product security, and handling various pallet sizes.

Super Power Stretch pallet wrappers

With the recent vast developments in film extruders and, to a lesser degree, in polymer engineering, stretch films can now be stretched up to 400% or even more. When stretched to 300%, twelve-micron films are only 3 microns thick when laid onto the pallet. The Power Pre Stretch pallet wrapper had to reinvent itself to take advantage of the extruder and film development. The superpower stretch or variable stretch wrappers are different in that they have two motors in the film carriage head with various developments in the film handling part of the carriage head. This makes it possible to stretch with more than 400 % pre-stretch; i.e. one meter of the film now becomes five meters. These machines are easy to operate from a control panel, producing a pre-stretch which can range from 10% to 400%. High pre-stretch reduces film consumption, enabling companies to achieve the best results at the lowest possible costs with optimal pallet stabilisation, which is crucial for product protection.

Inline Turn Table pallet wrapper

Inline is when a turn table wrapper is placed into a conveyor system and is integrated into the production line, which is ideal for those needing a fast pallet wrapping operation. These machines easily fit into or at the end of an existing conveyor system. The stretch film is applied automatically; it then wraps automatically and stops at the end of the cycle. The stretch film is automatically cut, and the tail is then pasted into place before the pallet moves off. Placing a turn table wrapper into a production line will offer the opportunity to reduce labour on each shift that it works. The automated wrapping process enhances efficiency and precision, ensuring consistent and cost-effective pallet wrapping.

Robot Pallet Wrapper

The latest technology in wrapping pallets is the robot. It operates by going self-propelled around the pallet to apply the film. Unlike a turn table or straddle machine, the robot will wrap a load that is larger than 1000 x 1200 pallets, i.e., 4 feet wide and 8 feet long. It could even wrap a portacabin or a load too heavy to be picked up by a forklift truck. It is very mobile, so it can easily go to where the load needs wrapping, thereby eliminating the need to move unwrapped loads through the factory to the pallet wrapper. One operator can work two or three machines simultaneously.

Robot pallet wrappers significantly improve efficiency within the supply chain by streamlining the wrapping process and reducing the need for manual labour.

Stand Alone Overhead Pallet wrapper.

These overhead pallet wrappers have their electrics and motors in the gantry above the wrapping arm, which rotates around the pallet. They are ideal for light, unstable loads, or very heavy loads. Pallet wrap machines, including automatic, manual, and mobile systems, offer significant benefits such as increasing production speed, accommodating different pallet sizes, and enhancing load stability. Food processing industries such as meat, poultry, or dairy, where the floor has to be hosed down, chilled or freezer plants, and dusty or dirty industries such as sawmills, brick & cement yards, or recycling plants. Anywhere

In-Line Overhead arm wrapper

Overhead straddle wrapping machines are ideal for unstable loads because this type of stretch wrapper allows loads to be quickly wrapped while moving on the conveyor. Overhead stretch wrappers are versatile. They can be employed in various ways: 1/ in a conveyor line, 2/ attached to the wall, and 3/ as a stand-alone unit. This technology is very versatile compared to a ring wrapper. It is swift at wrapping. The arm can be fitted with one or two film dispenser units. A stretch wrapping machine offers versatility and speed, making it an efficient solution for various warehouse operations.

In-Line Ring wrapper

Rotary ring wrappers straddle the pallet; they are unique because the film dispensers are fixed to a ring that allows them to rotate around the pallet. This type of wrapping machine is beneficial when wrapping unstable loads, including heavy and liquid loads, because the product remains static whilst being wrapped. The ring can be fitted with one or two film dispenser units. Stretch wrap machines, including robotic pallet wrapping machines and entry-level semi-automatic stretch wrap machines, offer efficiency and versatility for wrapping unstable loads.

Vertical ring wrappers

Loads can often be long and narrow (mouldings and extrusions), making them difficult to wrap by hand. Vertical Orbital wrappers are designed to wrap these products effectively and efficiently.

Vertical Orbital Wrappers can be semi or fully automatic. These machines enhance the wrapping process by providing greater efficiency and precision. The vertically positioned stretch wrap dispenser rotates the film around and under the load as it passes through the ring, significantly reducing the time it takes to wrap the loads by hand.

Hollow wrappers

These are designed to wrap endless products, such as car tyres, window frames and wound coils of flexible tubing.

Pallet wrap machines are highly efficient and flexible. They accommodate various pallet sizes and ensure the safe shipment of items.

Summary

The stretch wrap machine has revolutionised the way the packaging industry works by ensuring consistency and efficiency throughout the packaging process. Once, hand wrapping was the only option, but this was not cost-effective due to the time each load took to wrap and the ununiformed look of the end result. Today, every company has different operations and different packing machinery needs. Thanks to the wide range of pallet wrappers available today, every company can now choose a machine that is ideally suited to their individual needs. Pallet wrap machines, including automatic, manual, and mobile systems, offer increased production speed, accommodate different pallet sizes, enhance load stability, and come with various finance options, including renting and maintenance programs.

If you have any questions about your pallet wrapping project or requirements, we shall be happy to help you and answer any questions that you may have, not only about the pallet wrapping machine but the stretch film as well and the project that you have to wrap so that your product can travel and arrive to your customer without mishap.

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History of Pallet Stretch Wrap

Posted on August 5, 2024 by Richard Taszarek

You may not think so, but stretch wrap has a long history in industrial packaging. Indeed, it has become one of the fastest-growing industrial supply industries on the international market. Global demand for stretch wraps has been expected to increase steadily by at least 5.5% each year. It comes as no surprise, then, that stretch wrap has undergone a number of changes since its introduction to the chemical industry. The development of cast stretch wrap, known for its clarity, puncture resistance, and low noise when unwound, has played a significant role in the evolution of stretch wrap.

Early Days of Stretch Wrap

The LLDPE stretch wrap as we know it today was not always in the form we manufacture today. Like many other plastics, initial research that began its development was mostly created by pure accident. Polyethene itself is reported to have first been developed by Hans von Pechmann in Germany in 1898, decades before its real development began to take place fronted by the work of other chemists. It was a formation of the resin polymethylene – as it was named then – from the heating up of another chemical, diazomethane. The CH2 chains developed by this process would ignite further research and development around the world.

In the early days, clear pallet stretch wrap was used as a protective barrier for pallet loads, similar to cling film or rubber, to safeguard items from moisture, dirt, and debris during storage and shipping.

Industrial production for linear, low-density polyethene can be traced back to 1939 when Michael Perrin developed a process by which polyethene could be reproduced in a stable environment. Catalysts were created over the next few decades to further improve the polymerisation process, resulting in various temperatures and pressures by which polyethene could be produced. This included that of Karl Ziegler in 1953 and chemists at Phillips Petroleum, J. Paul Hogan and Robert Banks.

Both the Phillips and Ziegler catalysts were used to create high-density polyethene, which further developed its linear and low-density polyethene forms.

Industrial Development

With the plastic resins created by these processes, it became more apparent that industries could begin to use them for much more than solid plastic items. In fact, the linear nature of these polymers is exactly what led to the development of their thin film formation. Despite their thin appearance, the linear carbon polymers could hold together firmly, providing a plastic with excellent tensile strength. Packaging solutions were about to become much more appealing to thousands of industries.

The first patent for a stretch wrap machine was filed in the United States in 1967 by R. W. Burhop. This was perhaps the first real sign of stretch wrap from polyethene being used in an industrial setting and possibly spurred the rest of the industry to take notice and begin the process of pallet wrapping using the stretch wrap. Two forms of polyethene were in circulation then: LDPE and LLDPE. Hand pallet wrap is particularly suitable for small to medium operations, with options like flush core, extended core, and coreless film available.

LDPE has been noted as the polymer with the lowest tensile strength and higher ductility, which means it has become more often used for industries looking for strong containers and those requiring film wrap or plastic poly bags. On the other hand, LLDPE is used for far more applications. Industries use it not only for packaging film coverings but also for other solid items, including containers and even toys. Machine pallet wrap offers benefits in securing and protecting items during storage and transit, with features like recyclability and puncture resistance.

Different types of pallet wrap films, including hand film and machine film, are available to suit various operations and customer needs.

Layering Up the Stretch Film

When stretch wrap was first developed, it was created as a mono film with only one layer. By 1972, stretch film had become a staple of the pallet wrapping industry. This was the case up to the 1980s. The machine stretch pallet wrap of 23 microns was a single layer that had a stretch capacity of only around 10-15%. (Mechanical brake machines). As you can imagine, this lack of flexibility, alongside the development of larger pallets and containers, needed to be addressed. That is where the idea of changing from mono film to multi-layered film came from.

Pre-stretch pallet wrap is a film that has already been stretched during the production process. This requires less force when wrapping a pallet and reduces the amount of film needed.

Initially, all stretch film was made from either LDPE or PVC. Industrial professionals first assumed that the P.V.C. was the best choice due to its 50% stretch ability, compared to 30% LDPE, but it soon became apparent that P.V.C. was more prone to tears and breakage than its LDPE counterpart. As such, LDPE became the focus of the global stretch film revolution. This meant that LDPE mono film was in industrial production throughout the 1970s, and changes only came in the 1980s when demands by companies for affordability and resilience of their films had to be met, introducing the newly developed LLDPE – a film far more capable of the stretch and resilience companies were looking for.

Many industries in the United States in 1982 began to create films that were three layers thick. Each layer had a different property in the film, including the middle piece for flexibility, one outer layer for clinging, and one for a smooth outside finish to the film. The stretchability grew to 100% for the most cost-effective product. However, it was not long before more layers were added to the LLDPE process. (The reasoning for power stretch machines).

Demand for stretch wrap only increased as usage expanded globally. Demand doubled between 1985 and 1990 to 500 million lbs a year, doubling yet again in the following five years, meaning that both pricing and durability needed to be addressed for businesses to make a profit on both the supplier and consumer sides of the packaging industry, from one to three layers to the 1990s introducing 5-layered films. Today, films can stretch up to 400% at 23 microns, meaning that a single one-meter roll of film can stretch up to 5 metres without tearing. For the packaging and wrapping industries, this was the cost-effective product they were looking for.

Today’s Stretch Films

In the last decade, we have made great strides with our stretch films. Extrusion technology has become so advanced that we have seen thinner 17-micron films with seven layers able to stretch up to 250%+ of their starting length. Now, as recently as 36 months ago, we are seeing the development of films with 55 layers at 10 microns that can stretch up to 300%+. Clear pallet wrap is now widely used for stabilising loads and protecting goods from elements and damage during transportation.

Fifty-Five layered BETA NANO films are stronger (have better load retention properties) than, say, 12 to 20-linear layered films with metallasoline and similar chemicals added to give them that extra stretchability. When any 10-micron film is stretched to 300%, it is only 3 microns thick. Therefore (per square meter), the 55-layered film has a latticed work effect for its strength, while the lessor layered films only have a linear (one direction) additive for stretchability and strength. Stretch film wrap is essential for securing and protecting items on pallets during storage and shipping, ensuring stability and safety.

Q.E.D. BETA NANO 55 layered have better load retention and puncture-proof properties. However, a word of caution: do not expect you’re nearly new (2/3 years old, or certain types of new pallet wrappers, generally the bargain-priced ones) with a 300% power stretch to maximise the advantages of any of the 12-micron films. In short, they do not possess the stretching and application technology to successfully apply a 3-micron film to the load. However, as every load is different, there are always exceptions to the rule. Talk to us; it’s free!

An example of how BETA NANO Wrap reduced the client’s film consumption by 60% and pallet wrapping costs by 40%

Four Alpha 508 pallet wrappers processed 1000 rolls of 12 microns at 300% (i.e., one meter became four) and produced 11 million 800.000 meters of stretched film wrapping 238.000 pallets over 12 months without complaint from either the film or the Alpha pallet wrappers. The average cost of wrapping a pallet was only 18p. Payback on these machines was only seven months.

Hand stretch film is also designed to be applied manually with innovative hand pallet wrap dispensers. Different core types, such as flush core, extended core, and coreless film, are available, each suitable for different applications.

Q.E.D. A 12-micron, 55-layered film will stretch 300% and still offer high load retention properties. The 23-micron film will stretch to 400% and more. The Alpha 508 can successfully apply all of these types of film to the load every time. It’s just that it possesses state-of-the-art Technology.

Focus Packaging 01902 570 292. Email sales@focuspackaging.co.uk. www.palletwrapperuk.co.uk

Summary

The extrusion process is starting to become more useful for the packaging industry in its development of stretch film, and it has been the tireless efforts of just three businesses to create these films. Their commitment to very substantial amounts of capital expenditure to purchase state-of-the-art extruders and to commit to individual Research and Development projects in the user market is what has really started the process of creating thinner, more durable films for the market.

Focus Packaging can offer a range of machines and stretch films from 7 microns to 33 microns. Suitable for all types of pallet wrappers, mechanical brake power stretch pallet wrappers working with 150% to 300% stretch and now up to 400% plus stretch. Different machines for wrapping pallets can significantly reduce plastic and film usage, benefiting various volume users and load sizes.

The objective is to offer you the cheapest and best-wrapped pallets possible for your application.

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What Is Low-Density Polyethylene? (LDPE)

Posted on August 5, 2024 by Richard Taszarek

In any packaging industry, there is a tendency not to think too much about the origins of our most favoured products. The humble cardboard box, for example, does not get more than a bat of an eyelid to its history and its production value when used on a daily basis. The same can be said for one of the giants of the packaging industry –pallet stretch wrap. Few industries buying this revolutionary product realise that there is far more on the surface of their stretch film than simply having a great quality answer for protecting pallets and boxes of products.

Thinking outside of the box, we can see that there is certainly a rich history behind every roll of industrial stretch film. Starting from the beginning – what is low density polyethylene, and how does it contribute to the production of today’s stretch wrap? LDPE is known for its flexibility, toughness, and corrosion resistance, making it a popular choice for various engineering applications.

Creating Low-Density Polyethylene through Free Radical Polymerization

Stretch wrap is often created using linear low-density polyethene (LLDPE). In the beginning of plastics manufacturing, low density polyethylene was more prominent in the industry, however it is now more widely used for containers and non-stretching plastic products commonly used in the food packaging industry. As seen below, however, polyethylene in both liner and low density forms are most commonly used for different films, alongside other products and industrial requirements.

Polyethylene is created from elements found in natural resources: crude oil and some natural gases. Funnily enough, it was a complete accident that LDPE was formed in the first place. Ethylene gas plays a crucial role in the production of LDPE, as it is separated from the raw petroleum mixture and circulated through a compressor before being injected with air or peroxide initiators to initiate polymerization reactions in the tubular reactor. Researchers from both Germany and Italy in 1952 by the names of Karl Ziegler and Giulio Natta managed to create an environment where a new catalyst was produced for the free radical polymerization of ethylene. The process they developed was appropriately named the Ziegler-Natta catalyst, and their research earned them a Nobel prize together in 1963. The new aluminium-based catalyst they discovered allowed for the creation of LDPE to be permitted under conditions of lower pressure than previous polythene production would allow.

Poly plastics are created where the monomer, in this case ethylene, is forced to break by the use of a catalyst to join the open chains together. The double bonds holding the carbon atoms in ethylene are forcibly broken by the energy produced with the use of the catalyst, thus making each atom open to singular bonding, creating a linear, connecting chain of carbon and hydrogen molecules. The product, therefore, ends up having incredibly straight molecular lines, as shown below.

What happens to make polyethene capable of becoming low-density? Minimal amounts of a co-monomer are added to the chemical stock. The result of the process adds new branches to the molecular chain at irregular intervals. Random polymerisation takes place, and the smaller branching chains in the structure are what give the LDPE its low-density structure. Long chain branching affects the sealing temperature, barrier properties, density, tensile strength, and resilience of the LDPE, making it crucial in the industrial production process. The example below shows the smaller chain branch created when copolymerised with butane to create LLDPE, a process applied with low pressure first by DuPont Canada in the 1950s.

In recent years, the addition of a new chemical to the polymerisation process has resulted in a new addition to the polyethene family. Metallocene linear low density polyethylene (mLLDPE) is created when the catalyst used is a metalocene chemical. The mass of the final product is able to be thoroughly controlled through this polymerisation method, and the film produced is able to be incredibly thin, usually used for wrapping delicate food items.

In the manufacturing process of pallet stretch wrap, the film does not start life as a soft, supple material like the one it turns out to be after the production process ends. Rather, the end products of LDPE and LLDPE creation are small, irregularly shaped pellets of a hard, plastic resin. They are also not clear like the stretch film, having a milky or cloudy appearance. Despite this, they hold the potential to be melted down into stretch film through either the cast or blown process. This is because of the low-density molecular structure created during polymerisation.

Melting down the resin allows the plastic to turn molten, and the extrusion process involved in creating stretch wrap is as interesting as it is intensive. That, however, requires a far longer discussion.

Physical Properties of LDPE and LLDPE

Now that we understand LDPE is commonly used due to its chemical capabilities and physical properties, we can apply this to discovering the exact properties that make these plastics so attractive to the manufacturing and packaging industries.

The resins and films themselves have a number of key properties that are essential for packaging, including:

  • Low manufacturing and purchasing costs
  • Resistance to chemicals
  • Moisture-proof
  • Low resistance to heat for recyclability and turning into film

An industry has to take into consideration the advantages of the core materials when purchasing them. LDPE and LLDPE films have the ability to be used in varying gauges and are capable of protecting pallets from the majority of weather damage. Moisture is unable to pierce the plastic film, and the low costs of manufacturing many of the film types produced mean that the costs for repurchasing new rolls of the product are reduced, providing savings across the board for packaging industries. Additionally, the low cost of LDPE production using low-pressure technology and its high-efficiency production process make it an appealing choice for engineering applications.

Advantages of Low-Density Polyethylene;- Pallet Stretch Wrap

Why should you consider pallet stretch wrap, then, as your trusted packaging solution? Its advantages are numerous. Low-density polyethene is a versatile plastic that can be used for various applications, in particular for films, pipes, and containers. It is also widely used in industrial packaging for clothing, electronics, and other industrial items to meet specific product requirements and provide adequate protection. The advances in stretch film production with the introduction of new machinery, however, have allowed us to get even closer to the best of polyethene’s capabilities for industrial uses with multiple machine-grade options available.

This means that pallet stretch wrap is one of the most widely used packaging products to date. Saving money for businesses is one of its top advantages in both manufacturing and purchasing. The high-quality protection it provides for products in transit and storage, too, enables LDPE and LLDPE stretch wrap to leapt ahead in the packaging world. LDPE materials are known for their flexibility, transparency, and moisture resistance, making them ideal for plastic packaging film, disposable plastic products, pipes, and medical/healthcare items. LDPE plastic is also recyclable and widely used in agriculture for irrigation systems and in the packaging industry for food and industrial products. Not using stretch wrap to protect your pallets and packages means missing out on the world’s leading packaging solution.

However, choosing the right kind of stretch wrap for your business is not as easy as it appears. Not only do you have to consider the type of film (cast or blown), but the gauge required for strength and protection depends on the products you supply. The other half of the equation for cost-effective and low-carbon pallet wrapping is the pallet wrapper. They vary so much in performance that the wrapped cost of the average pallet can range by nearly 500% (from 16p to 80p) just by wrapping the same load from different machines with different films. Focus Packaging offers free, confidential, and unbiased professional advice in this area.

Focus Packaging 01902 570 292. sales@focuspackaging.co.uk. www.palletwrapperuk.co.uk

Stepping Stone to the Future

Stretch wrap has come a long way from its early days in production. From Germany, LDPE and LLDPE resins have been transported worldwide and used in all sorts of industries. As the products we ship and wrap have changed, the original mono extrusion process, too, has changed. The history of stretch wrap is as elaborate as its creation, and every roll of film has decades of hard work and effort behind it.

LDPE recycling is crucial for environmental sustainability, but it faces challenges such as contamination from agricultural use, the need for proper cleaning and sorting, and the difficulties faced by recycling machines.

The management of plastic waste is essential to mitigate environmental impact. Proper recycling and waste management are key to addressing the issue of plastic pollution.

Advancements in processing LDPE, including the collection of contaminated film, cleaning, sorting, and the use of special recycling machines, are making the recycling process more efficient and expanding its potential uses.

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CoBot Davit Lifts

Posted on June 22, 2020 by adminuser

The Stationary CoBot Lift is like an exoskeleton for CoBots mounted on the floor. It boosts the CoBot’s payload from 10 kg to 30 kg.

The Mobile CoBot Integrates the robot, controller, teach pendant, vacuum tube lift & pump and crane as a single mobile unit for maximum flexibility and quick installation.

 

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Mobile Industrial Robots (MiR)

Posted on February 20, 2020 by adminuser

Motorised Independent Robots (MiR) make your employees more efficient by allowing them to focus on higher-value activities, while shortening lead time and reducing the risk of bottlenecks. They optimise safety and reduce risk of injury by reducing the need of forklift usage to move pallets amongst people.

 

 

 

 

 

Why is it ideal for your business?

  • Cheaper than labour
  • Dedicated means of carriage with in built safety features
  • Removes the need for labour to move products around the workshop
  • It can work 24 hours a day
  • It can be adapted to different function like carrying, towing and lifting.
  • It can move collaborative robots (cobots) to different work locations.
  • Can help reduce the amount of conveyors for transporting pallets and components.

Optimise your workflow, increase productivity and reduce costs.
Hospitals, Care Homes, Laboratories, Manufacturing, Logistics, Food & Drink, Warehousing and Distribution.
As well as bespoke applications catering to your work environment.

 

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Cobot Applications

Posted on February 20, 2020 by adminuser

Collaborative robots are designed to increase productivity and reduce labour. They can also work safely alongside operatives without guarding or they can work independently and unsupervised.
 

Sold to over 50 countries and operating in the following industries

  • Aerospace and Defense
    • Work round the clock running unmanned shifts.
  • Automotive and subcontractor
    • integrates into existing production lines to take over critical and precision tasks.
  • Food & Agriculture
    • Keep food and ingredient wastage to a minimum while which working around the clock.
  • Electronics & Technology
    • Fast to adapt to new tasks, changes and working with dangerous machinery.
  • Furniture & Equipment
    • take over labour intensive & repetitive take.
    • Increase levels of precision and consistency in production.
  • Metal & Machining
    • Their accuracy and precision make them a must for this industry.
  • Pharma & Chemistry
    • Taking over human tasks will reduce the risk of contamination and human errors with sterile handling
  • Plastic & Polymers
    • can be used across all areas of plastic and polymer production at vary temperature ranges which will extend production capabilities.
  • Scientific & Research
    • Accuracy and reliability makes it a valuable tool for teaching and development at universities and research institutions.
  • Finishing & Polishing
    • Eliminates the human variance in the quality of finish. Never gets fed up with the job at hand.
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Things to Consider When Investing in a Pallet Wrapping Machine?

Posted on June 27, 2017 by adminuser

At Pallet Wrapper UK, we are aware that stretch wrapping plays an integral role in the shipping of different kinds of products, from concrete to cereal and much more. Each and every line of production is different and every warehouse has its own speciality. Companies face unique challenges relevant to their line of business, levels of staffing, products or floor space and that is why we carry a vast array of pallet stretch wrapper machines for you to choose from.

# Will the pallet wrapping machine be able to keep up with your production?

Our robust pallet wrapping equipment is specifically designed to work quickly whilst maintaining a high standard of quality. By investing in our equipment, you can be confident that the wrapping machine will not cause any delay in production.

# Is the equipment CE and H&S compliant?

Our complete range of automatic and semi-automatic pallet wrapping machines are CE and H&S compliant. We offer 12 months guarantee on all parts, as well as offering professional help for any technical issues you may have.

# Can the pallet wrapping machine be customised?

At Pallet Wrapper UK, we carry a comprehensive selection of the industries best stretch wrap machines. However, in case you have a requirement that our products are unable to fulfill, we can design and build a machine according to your exact specifications and needs. Feel free to call us to discuss your exact pallet wrapping needs.

# Are financing options available?

To ensure that you are able to acquire the best pallet wrapping machine, we have put together a lucrative financing option. We provide lease, as well as, lease purchase options that require you to pay a fixed monthly repayment within your budget. With a small initial capital investment, you can get the equipment you need.

Our stretch film machine provides wonderful opportunities for savings, enhanced production and safety. If you are wrapping pallets manually, it is time to upgrade your production facility with the help of Pallet Wrapper UK. To learn more about our machines and finance options, contact us today.

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4 Simple Steps To Help Speed Up Your Existing Packaging Operation

Posted on June 9, 2017 by adminuser

Your customers will be very disappointed, if their products do not reach them on the promised date and time and in good condition. At PalletWrapperUK Ltd, we recognise efficiency and speed of the packaging operation is key to products being delivered to your customers on time.

To safeguard your reputation and your customers’ trust, our professionals have compiled 4 simple steps to optimise your packaging operation. Take a look below.

# Evaluate your existing packing stations

Assess the current state of your packing stations and make sure that they are organised and carry everything your packers need.

Easy access to packing materials will allow your packers to work faster and more efficiently. Also, it will limit the probability of packaging-related injuries.

# Review your packaging

In the packaging industry, time is of the essence. If your packers are spending a lot of time assembling and sealing boxes, you probably need to modify your existing packaging.

As an example, you may opt for solutions such as, crash lock boxes, self-sealing or possibly invest in a used pallet wrapper machine from PalletWrapperUK Ltd. These solutions can significantly increase your productivity.

# Consider a box range upgrade

Estimating your box range will enable you to provide a better service when it comes to packing individual products, along with speeding up the whole process. Successful evaluation will lead to huge savings on material costs.

# Adopt packaging automation

A great way to increase packing speed is packaging automation. At PalletWrapperUK Ltd, we can supply a wide range of pallet wrapping machines that can fully automate your packaging operation. Our machines are designed with all the latest cutting-edge technology. Having the correct machine will increase productivity and enhance your return on investment.

We, at PalletWrapperUK Ltd, can conduct a full review of your packaging operation and identify the areas requiring improvements. Our comprehensive line of automatic and semi-automatic pallet wrapping machines are available with our best price guarantee. For further details on the services and products we offer contact us today.

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Beyond Just Packing: 9 Packaging Essentials You Should Be aware of

Posted on April 12, 2017 by adminuser

Good packaging is not just confined to the work of your pallet wrapping machine. A factor that might not seem so important but plays a vital role in customer experience is the packaging of your product. A Pallet Wrapping machine ensures your products arrive safely and are protected throughout their stressful journey. Pallet wrapping machines are a cost effective way of ensuring your products reach your customer in pristine a condition.

Here are some essentials to keep in mind whilst designing the packaging for your product.

  1. Brand Logo: Make sure your brand logo is printed on the insides of the package for that strong branding presence, which in turn encourages customer to choose your company again. Did you know that pallet stretch wrap can also be printed with your logo; there are several colours and black for security.
  2. Convenient Opening: Provide an easy-to-open package for convenience. A simple tear strip or zig-zag opening should do the trick.
  3. Personalisation: Print a short personal message on the box. This shows that you are customer-friendly and care about their needs.
  4. Sealing: Apart from the pallet, machine sealing the box outside, a self-sealing tape on the outside of the box that not only holds the box together, but also keeps those messy-looking taped seal away is a good choice.
  5. Extra Adhesives: Provide an extra seal that makes it easier to repack the box, in case the customer needs to return the product.
  6. Easier Assembly: Crash-lock bases are a great way to save time during the erection of your carton. They are easy to assemble. You can now also have self- adhesive flaps on your cartons…
  7. Recycling: Make the package recyclable. This is an environment-friendly option that allows the customer to recycle packaging instead of sending it to a waste fill site. It improves their green credentials and reduces packaging waste returns
  8. Label Indicators: Print label indicators on the package. This makes it convenient for packers to know where they should paste the labels.
  9. Security: The design of the box should be tamper-proof and stress-resistant. Leave no room for gaps in the package for meddling with the product or the package itself.

With these points at hand, you can now ensure not only enhanced customer satisfaction and a high chance of repeat business, but also a higher standard of quality and security for your product.

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