Don’t Buy a Stupid Stretch Wrapper: 2

ESTABLISHING YOUR BASELINE IN STRETCH WRAPPING.

In part 2 we are going to talk about establishing a baseline. Perhaps you have heard some of these statements: “Without Data you are just another person with an opinion” – Dr. Deming.dr deming stretch wrap

Or the words of Lord Kelvin, “If you cant measure it, you cant improve it.”
kelvin stretch wrap

First, lets define containment force with regards to pallet stretch wrapping. When you wrap your pallet with stretch film, you have the decision of how much force you want that film to squeeze your pallet with. You can wrap the pallet very loosely, which will allow for only a dust cover, or you can really pull the film tightly. The pressure that the film applies to the pallet is containment force.

Read more about containment force and stretch film properties HERE.

Unlike others who design special tools to measure containment, Highlight Industries conforms to ASTM D4649-03 Annex A1. This is a documented and repeatable method to measure containment on your pallets. (Please note that we also offer tools to allow you to measure your containment).

You may ask yourself, “Self, why would I want to use this method instead of others who may incorporate a cool gadget?”

The answer is simple: Highlight Industries helps you develop your packaging standards. Isn’t it important to have a nationally recognized living document that is available to provide your customers on exactly what you have done? Instead of them having to buy custom measuring tools that may not be clearly documented in their methodology, and could also allow for user variances.

For more information and tools to help you measure your containment, please contact Highlight Industries. Tune into the same Bat Channel and at the same Bat Time to read Part 3 of our Series….Improving your methods.

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Don’t Buy A Stupid Stretch Wrapper

Don’t buy a stupid stretch wrapper (from a stupid stretch wrapper company)!
Part 1

They all go round and round round and up and down right?
Wrong!

How you stretch wrap your pallets will make or break your customer’s relationship with their customer, and ultimately their relationship with you!

Image result for business relationships

At Highlight Industries, we pride ourselves in taking a scientific approach to stretch wrapping pallets. Over the years, salespeople have all been trained that if pallets fail, the solution is to put more wrap on the pallet. Maybe more at the top, maybe more at the bottom; perhaps, eliminate the vibration in the middle. uneven stretch film application

This ‘solution’ can be inconsistent, inefficient, and potentially costly. There has never been a “this is how you do it” fix… until now.

Introducing the Highlight Industries stretch tools App!

Among other things, such as a mil to gauge convertor, diagonal calculator, 20 vs 30 film comparison, cost to wrap, etc,  the Stretch Tools App has a containment force calculator.

containment force calcuation

You may ask yourself, “self, what does that do?” The answer is: Highlight Industries Containment Force Calculator will take important criteria (load value, dimensions, distance to be shipped, etc) and deliver an estimated containment requirement (the force that provides to hold your products in place), as well as the estimated amount of film that should be used to wrap the load and achieve this containment requirement.

Containment force

The Stretch Tools App eliminates the guess work when wrapping. You’ll always have the correct amount of film to keep your products safe; not so little that it falls apart, and not so much that you’ll be wasting money over-wrapping.

This app is available in Apple and Android versions.

So while other companies try to tell you the importance of containment, Highlight Industries shows you the amount required……very smart!

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Elastic Properties of Stretch Film

Stretch film does not get tighter over time.

When an elastic material is deformed due to an external force (example: your hands stretching a rubber band, stretching film), it experiences internal forces that oppose the deformation and restore it to its original state (the rubber band ‘pushing’ back after you slack on stretching it, film ‘relaxing’)  if the external force is no longer applied.

elastic rubber band

 

This is elastic recovery. Elastic recovery exudes constant pressure until the original state of the elastic item is attained.

This pressure is what keeps items tightly bound when it comes to stretch wrapping loads (or binding items with rubber bands). This ability to tightly bind pallets and products is why stretch film is such an effective packaging option.

This constant pressure also means that constant force is also being applied to whatever is halting full elastic recovery.

As seen with tests run on Highlight’s Film Test Stand: Labview Document

If that force is great enough, when applied over time, it can crush particles in items such as boxes, containers, and even watermelons. In the case of stretch wrapping, this is why pre-stretch levels, film force, and containment force are so important: you want enough force to contain your products, but not so much that you damage them.

Crushed load

 

Stretch film (and rubber bands) do not get tighter over time – it is the recovery of the elastic properties that create pressure and force necessary to contain loads. And if the force is too great, this pressure can also crush melons.

 

 

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Everyone should try to “Catch One of These Predators”

Sit down Chris Hansen, these PREDATOR STRETCH WRAPPERS are eating the competition. Predator Pallet Wrap Machines are hands down the best value in the industry. Available in multiple levels, we have the correct machine for your company. If you are just starting out and looking for your first pallet wrapper, try the PREDATOR SS.

Predator® SS Semi-Automatic Turntable Stretch Wrapper with Simplified Stretch

Simple and easy to use, the Predator® SS is the affordable solution to stretch wrap your load without stretching your budget. The Predator® SS is loaded with features, including top and bottom counters, photo eye, and two (2) wrapping modes.

State-of-the-art INFO screen shows current machine operation and makes troubleshooting easy. The Simplified Stretch allows you to precisely adjust your stretch level and film force on your load with the turn of a knob.

If you are looking to step up and take advantage of a powered pre-stretch system, The PREDATOR XS (and it’s X-tra Stuff) may be right for you.

predator-xs-01

Predator® XS Semi-Automatic Turntable Stretch Wrapper 

The Predator® XS is designed with extra features that surpass all preconceived notions of performance and value in semi-automatic systems.

The Predator® XS provides greater film savings as well as improved performance with Select-Stretch™. Allen-Bradley PLC, automatic film cut, AC drives, and Fast Film Feed make the Predator® XS the most advanced and reliable system available.

Perhaps you are ready to step up to a fully automatic machine, PREDATOR PLATINUM is what the doctor ordered.

Predator® Platinum Fully Automatic Turntable Stretch Wrapper

The Predator® Platinum improves productivity by automatically wrapping loads with just the push of the remote.The automatic film attach, cut, and wipe down is the most advanced in the industry and improves productivity by up to 40%.

The Predator® Platinum is a true fully automatic system with built-in features for increased productivity that are not available on other simpler automatics.

Please contact Highlight Industries to determine which is best for your application. 1.800.531.2465

Highlight Worldwide

Highlight is the world leader in stretch film testing and load containment technology, and we just completed our Worldwide Technology Tour.

March 24, 2015 – NPE in Orlando, Florida

Highlight presented at the ExxonMobil Technology Symposium

 

April 7, 2015 – ISTA Transpack Forum in Orlando, Florida

Highlight presented on new research for predicting load stability at the 3 day conference on Transport Packaging. We also exhibited at the Equipment Supplier’s Forum.

 

April 13, 2015 – Ergis Group, Poland

Has 2 Highlight Test Stands and portable load cell testing systems and has been using Highlight technology for over 10 years. We reviewed the European Containment Standards.

 

April 15, 2015 – AMI Conference, Cologne Germany

Presented ‘Stretch Film Testing Methods for Improved Load Containment’ and met with resin producers from 23 countries.

 

April 20, 2015 – Universal Packaging, New Zealand

Universal Packaging, who currently uses Highlight’s portable film testing systems, met at our Grand Rapids, Michigan Headquarters to look into investing in the Highlight Test Cube for containment testing.

 

April 23, 2015 – DOW Chemical’s Materials University, Freeport Texas

Event at DOW’s facilities focused on flexible packaging processing and materials testing. Highlight presented to groups of industry professionals on the use and significance of stretch film as a unit load stabilizer.

 

In the last 60 days Highlight met with resin companies and film companies from around the world to share the most advanced stretch film and load containment technology available. We are always continuing our efforts to bring you the highest quality, highest value, and highest technology test systems in the world.

High Speed Wrapping and Film Breakage

with Luke Venechuk, Sr Packaging Engineer

speed dial pic

What happens when films are run at high wrapping speeds? Why do films breaks increase so much for these applications? Will the same film perform differently at differently at 12, 24, and 40 RPM?

There are some people in our industry that believe film breaks increase at high speeds because the film heats up and lose its integrity. To find out whether this theory is correct Highlight ran films at different speeds and measured its properties to compare.

The graph below shows a single film being ran at speeds equivalent to 12, 24 and 40 RPM:

graph pic

 

In the graph above we can see that the force to stretch the film (on the left-hand Y-axis) increases slightly as the application speed increases, this is about a 2% increase if we look at the force to stretch at 200% (stretch level is the bottom X-axis, and 200% is within the middle red circle).

We can also see that the stretch at break or ultimate stretch does not change significantly (the right hand red circle).

The increase in force is due to the fact that we’re doing the same work, stretching the film to the same level, in a shorter amount of time, which means we have to pull a little harder to end up with the same result.

There are some small differences that take place for the film at different speeds, but it’s certainly not anything that would cause the film to break.

So what is causing film breaks at high speeds?

Highlight found that the cause of most film breaks at high application speeds is due to poor corner compensation. Corner Compensation is a system within most stretch wrappers that increases the film payout rate for the corners of the load and slows the film speed on the sides of the load while wrapping, usually by changing the speed of the prestretch rollers throughout the wrap cycle

Here’s a top view of a rotating load:

rotating load pic

Corner Compensation is needed as the film demand is constantly changing as the four-sided load rotates. Here’s an example of a changing demand rate through one revolution of wrapping:

graph 2

As we wrap faster and faster, the equipment has less time to change its film speed, so the rate of acceleration for the film delivery gets exponentially higher.

At 12 RPM the film goes from 131 to 200 ft/min in .66 seconds. At 50 RPM the film goes from 550 to 835 ft/min in .16 seconds.

graph 3

This rapid acceleration creates more stress and is the reason why we see more film failures at high wrapping speeds. This is compounded by the fact that many corner compensation systems perform worse as they age, becoming “out of sync” with the wrapping needs of the rotating load.

What’s the solution to all of this?

The correct approach with the film or the equipment can reduce these film breaks.

For the film: high ultimate stretch levels allow films to absorb sudden spikes in stretch levels without breaking. It may be possible that very stiff films will resist stretching when exposed to spikes in stress.

For the equipment: The best solution is to fix the corner compensation system. Highlight responds to corner demand and changing film feed rates without the constant acceleration and deceleration of the prestretch roller, where the most stress on the film occurs. By moving our corner compensation from the high stress area of the prestretch section to the low stress area after that we can almost completely eliminate film breaks due to corner compensation at high speeds.

For more information visit www.highlightindustries.com or call us at 800-531-2465

 

Machine Spotlight: Complete Inline System

Highlight builds many custom inline systems and specialized machines to help customers with their specific packaging challenges.

Model:

Revolver R36 Orbital Stretch Wrapper, Custom Magnum 4500 SD-R Top and Bottom Case Sealer, Saturn SAS-3600 SS Side Strapping System.


Industry:

A gear and drive motor manufacturer.


Primary Project Challenge:

Provide an economical and efficient alternative to costly foam-in-place packaging while protecting product and readying it for transit.


Problem Solving Features:

This specialized inline system creates a smooth path for the product to travel down, starting with the Revolver system centering the product and securing it to a corrugated base with stretch film, providing an inexpensive and protective package.

The package then goes to the Magnum case sealer where a case is placed over the product on the corrugated base, and then taped using two bottom tape heads and one top tape head.

The product, now sealed in a case, moves onto a special conveyor that shifts the product to one side to enter the Saturn strapper, which applied three consecutive straps to ensure the product stays in its case. The straps are heat sealed on the side so as to not interrupt the conveyor flow.


Watch the system in action:

Section 179 Tax Deduction Extended

Information from http://www.section179.org/ on  Section 179 tax deduction extending through the end of the year:

H.R. 5771 (the Tax Extenders Bill) passed by the House on Dec 3, 2014 was voted on and passed by the Senate on Dec 16, 2014 retroactively expanding the Section 179 deduction limits thru 12/31/2014.

Only this 2014 tax year will be covered by this measure – therefore it is a good business decision for many to buy/finance equipment immediately to make the December 31, 2014 cutoff for the write-off provisions.

Repeat, this new provision does NOT cover tax year 2015, the law covers tax year 2014 only! To obtain Section 179 Qualified Financing for your business, you must apply immediately to make the cut-off at midnight 12/31/2014.

Keep up with the Bill that reinstates the limit on Section 179 to $500,000 as well as reinstates 50% Bonus Depreciation: H.R. 5771: Tax Increase Prevention Act of 2014 (aka Tax Extenders Bill) via govtrack here :http://link.crestcapital.com/hr5771

Technically, the bill is a one-year, retroactive extension of the tax breaks, even though it only lasts through the end of the month. This site will be updated to reflect these changes shortly.

For more info on this, check with your financial adviser or go to http://www.section179.org/

Stretch Film Printing System

The Highlight Stretch Film Printing System prints your message directly onto standard stretch film for improved product identification, tamper evidence, and reduced pilferage.

Your company’s message is easy to customize using flexible rubber type. Three selectable printing programs apply your message on-demand, at top of your load, continuously during wrapping, or on demand with the push of a button.

The standard rubber type is one inch high, and custom type logos can be created. Changing messages and date codes only takes seconds. The special alcohol-based quick-drying ink system will not rub off or transfer to your product. The ink is contained in a disposable ink roll and is easy to change. Estimated ink roll life is 250,000 continuous characters; actual life is dependent on type size, usage, and environment.

The Highlight Stretch Film Printing System is an easy solution for printing on your loads to keep your products safe and identifiable. The system is available on select Synergy and Freedom Stretch Wrapping Systems.

 

 Stretch Film Printing System