Our Answer to Facilitator's Question

Qns:Under what circumstances does film base wrapping become a prefer choice of logistical packaging instead of corrugated material.

Shrink Wrap VS. Corrugated Boxes (Cardboard)

STORING,

• Corrugated packing collects moisture, which makes the load unstable and, therefore, unfit for top-on-top storage.


• Film wrapping gives optimum stacking possibilities; up to eight layers is possible and also protects the pallet loads from dust and moisture.

http://www.appliancemagazine.com/editorial.php?article=61&zone=210&first=1

SHIPPING,

• Film wrapping stabilises pallet loads and prevents split deliveries. In addition, it also protects the contents of the pallet from weather and dust in transit.

http://www.generalpackaging.co.uk/pm-shrinkwrap.asp

COST,
This link illustrates the cost comparison between film wrapping and corrugated packaging. http://aquatechnology.net/shrinkcomparison.html

The company is aqua technology company that requires packing of bottles to be done. The comparison is done based on the cost of packing 1,500,000 bottles per year. It shows that the cost of film wrapping is cheaper than that of corrugated packaging. Therefore it is fair to say that in general film wrapping is a cheaper alternative as compared to corrugated packaging.

FLEXIBILITY,

• A shrink-wrapping system combines high quality modular construction with state-of-the-art process control.


• Quick and easy change over and lack of change parts make it ideal for those companies who run production lines that are not dedicated or where regular pack and size changes take place.


• Providing complete flexibility and ease of operation, the system can be expanded or simplified on the user's premises.

This means that the customer can upgrade their machine at any time in a simple, practical and cost effective way, whilst at the same time future-proofing their initial capital investment.

Re-Definition of Shrink Wrapping

What is Shrink Wrap/Film Base Wrapping?

Shrink wrap or shrink film, is a material made up of polymer plastic film.

When heat is applied to this material it shrinks tightly over whatever it was covering.

It is commonly used as an overwrap on many types of packaging: CDs, DVDs, cartons, books, beverage cans, large appliances, pallet loads or even food etc.

In addition, it is also used to cover boats after manufacture and for winter storage. Shrink bands are applied over parts of packages for tamper resistance or labels. It can also combine two packages or parts.

The most commonly used shrink wrap is polyolefin. It is available in a variety of thicknesses, clarities, strengths and shrink ratios. The two primary films are either crosslinked, or non crosslinked. Other shrink films include PVC and several other compositions.

A shrink film can be made to shrink in one direction (unidirectional or mono-directional) or in both directions (bidirectional).

Current trends are to improve film properties which may lead to reduced caliper (source reduction) and to improve process efficiency (cost and energy savings).

Corrugated Packaging

Corrugated packaging also contributes to simplifying the supply chain and increasing efficiency by:

Providing efficient handling

It is easy to erect and can be filled at high speed on automated packing lines. Thanks to its lightweight, knockdown ability and stackabililty, corrugated packaging is easy to transport, handle, store and to dispose of. It also optimises floor space allocated to storage at all points of the logistics chain. Furthermore, it offers efficient and user-friendly solutions for bringing the products to the shelves in the stores.

Transporting more of your product and cutting down the kilometers!

Using corrugated packaging provides maximum stacking and space use, which guarantees that each vehicle can take on its full capacity. This means fewer trucks on the road, less traffic, reduced CO2 emissions and real cost saving.

Compared to reusable systems, in an open loop system, corrugated single trip packaging is established to be the best packaging solution especially when it involves long distances because trucks can transport 3 times as many empty corrugated packaging and fit up to 30% more packaged goods on a pallet.

Tracing goods efficiently

Corrugated packaging strictly complies with the European legislation on traceability; by enabling the tracking and tracing of product packed, corrugated helps to guaranty food safety. It is well known that clear product identification boosts the efficiency of the whole logistics process.

Corrugated is an ideal packaging for printing all types of codes, either when packaging is manufactured or at the packing line, these codes are the key to computerised inventory systems which track the product through the chain.

Full traceability reduces stock loss and improves shelf availability of products, enhancing consumer satisfaction and loyalty. The industry is also investigating future issues such as the development of intelligent packaging, where key business developments especially on RFID are likely to take place in the coming years.

Offering a user friendly packaging solution

Corrugated packaging removes complexity in the chain: Corrugated is a simple and transparent packaging solution; there’s no hidden cost and it does not require washing, unnecessary administration work or extra storage space.

Source : http://www.fefco.org/

Other benefits of corrugated packaging can be found at http://www.corrugated.org/Basics/WhyCorrugated.aspx

Corrugated Packaging

What is Corrugated boxes?

Corrugated boxes are commonly known as cardboxes. Corrugated is made of paper and has an arched layer, called "fluting", between smooth sheets, called "liner." The corrugated most commonly used to make boxes has one layer of fluting between two smooth sheets.

Corrugated is an extremely durable, versatile, economical and lightweight material used for custom-manufactured shipping containers, packaging and point-of-purchase displays, in addition to numerous non-traditional applications ranging from pallets to children's toys to furniture.

It is a complete, high-performance material design, manufacturing and delivery system.

Corrugated is the preferred packaging material because it is:

• Durable
• Versatile
• Lightweight
• Sustainable
• Environmentally Responsible
• Made from a Renewable Resource
• Customizable
• Protective
• Graphically Appealing
• Cost-Effective

Source: http://www.corrugated.org/

The picture on the left is that of a standard 20Footer General Purpose Container. The 20 Footer container is the most common container worldwide. However, the 40-ft container is increasingly replacing it, particularly because transportation costs tend to vary more per container than per foot or ton.

As a general industry rule, ISO shipping containers are available in 20', 40', and 45’ sizes and are made of steel or aluminum. The height of a typical general purpose container is 8’6”. Containers that are 9'6" high are considered high cubes.

Types

Various container types are available for different needs:

• General purpose dry van for boxes, cartons, cases, sacks, bales, pallets, drums in standard, high or half height
• High cube palletwide containers for compatibility
• Temperature controlled from −25 °C to +25 °C reefer
• Open top bulktainers for bulk minerals, heavy machinery
• Open side for loading oversize pallet
• Flushfolding flat-rack containers for heavy and bulky semi-finished goods, out of gauge cargo
• Platform or bolster for barrels and drums, crates, cable drums, out of gauge cargo, machinery, and processed timber
• Ventilated containers for organic products requiring ventilation
• Tank containers for bulk liquids and DG
• Rolling floor for difficult to handle cargo
• Gas bottle
• Generator
• Collapsible ISO
• Swapbody

Handling Equipments

Trolleys


Pallet Jacks


Electrical Stacker

Adjustable-Width Pallet Jacks

Strapping Products

Strapping on be done by strapping the products onto pallets or, simply by strapping the bundle of products together to secure the cargo.

Manual Plastic / Steel Strapping
Plastic Hand Strapping Tool











Tensioning / Sealing











Semi-Automated Plastic/Steel Strapping Machine

Shrink-Wrapping Process

Shrink-wrapping (or more accurately "Stretch-wrapping") is a packaging technique used in industry to secure items to a pallet. It entails using a roll of thin, stretchable plastic film to apply many layers of holding power for the job. Often people do not put enough thought into this chore and the results are not as effective as they could be.

There is an art and etiquette to shrink-wrapping objects to a pallet. Read this article for tips on proper techniques and time-savers while pallet-wrapping.

Steps

1. Choose the right pallet: Place your items to be shipped or stored onto a sturdy pallet. Try to find a pallet that is just the right size to accommodate the amount of boxes or other materials you are palletizing. This will help to save you from tearing the plastic film on sharp corners of the pallet.
• Be certain that the items you are about to wrap are as close to one another on the pallet as possible. If they have room to shift around after you've applied the shrink wrap the entire unit will become loose and ineffective. Brace items against one another
  
  
2. Make it easy: Set your pallet to be wrapped on a short stack of empty pallets. This will make it easier to wrap since you won't need to bend over so far. It helps to set your pallet diagonally at a 45 degree angle rather than square on the stack (so that the bottoms of each corner overlaps the top edge of the stack beneath). Make sure the pallet does not wobble up there!
   
   
3. Attaching the shrinkwrap: Take your shrinkwrap roll and peel out about a yard of plastic. Squeeze 8 inches or so of the end together into a loose rope shape and thread this through and around one corner of the pallet. Don't bother tying a knot. Simply hold the end snug as you fold the rest of the yard over it. The plastic sticks to itself so this should be sufficient to keep it from pulling loose when you begin to wrap.
   
   
4. Make your foundation strong: Wrap around the base of the pallet in the same direction that was begun when you made the fold. Ensure that you wrap the base enough times so that your plastic will not slip off. This is the most important step since the goal is to keep your goods on the pallet. Wrap that base at least four or five times, being careful to allow the edge of the wrap to go underneath the corners. Pull the roll tightly just before going around each corner.
   
   
5. Secure the goods: Basically you want the entire pallet to feel like a unit; Everything should move as one, without wobbling. With that in mind, work your way up from the base so that the bottom boxes are first to be "married" with the pallet. Continue wrapping so that the next layer is joined firmly to the first and so on. Be sure to take as much stretch as possible out of the plastic film while you are wrapping.
   
   
6. Test and finish: When you reach the top of the pallet you can either end there or wrap back down the pallet again. To decide what is needed, try pushing the upper boxes to see if the load seems tight or loose. If you see the plastic ripple or the stack wobble, you either didn't wrap tightly enough or it needs more layers. Go around it a few more times, working your way back down to the base. When the stack is firm, tear the film apart from the roll and fold the end of it under the edge of one of the wraps at the side of the pallet. This will keep your wrap job from coming undone.

Tips

• Do not tie the shrinkwrap to the pallet with a knot! This is an issue of both etiquette and time-economy. Not only does it take you extra time to make the knot, but somewhere down the line someone will have to take out their knife and sever that knot. The plastic film sticks to itself, so knots are unnecessary.
  
  
• For a little added strength at the end of wrapping move to the center of your pallet and go around one more time. As you go around flip your shrink wrap to create an X in the wrap. This allows you to pull much harder without breaking the wrap and also adds stability.

Warnings

• Do not wrap too loosely as this will allow the plastic wrap to stretch while in transit. Always stretch the plastic to the point of almost breaking. The more "stretch" you can take out of it the more firmly it will hold.

Latest Equipments for Packaging

Angle Guards are used to secure cartons & guard the edge of the cartons
from damages/impacts.

Plastic Film Wrapping (Shrink Wrap)


Manual Wrapping

Manual Wrapping whereby the personnel will just move around & secure the load on the pallets. Rather tedious but cost saving. Good for irregular shapes.

Automated Wrapping

Automatic Pallet Stretch Wrapping Turntable Machines

The machine comes with a turn table.
It automatically wraps. The machine contains a remote start/stop switch so that forklift/stacker operators need not leave their equipments to cut or attach the film & start/stop the machine. Convenient & efficient but consumes electricity.

What is Shrink Wrapping

Shrink-wrap is manufactured and classified as a plastic product. During manufacturing, the plastic-based material is manipulated to produce a continuous thin film that is then tightly wound onto thick, layered cardboard rolls commonly referred to as cores.

Shrink-wrap rolls are produced in various lengths and widths; roll lengths range from 1,100 to 17,500 linear feet and roll widths range from 3 to 70 inches. Available roll lengths and widths vary depending upon the shrink-wrap wind and type.

There are two ways in which to wind shrink-wrap onto a core: Singlewound and Centerfold. Singlewound means that the shrink-wrap is wound onto a core in a single layer. Centerfold means that the shrink-wrap is folded in the center before it is wound onto a core in a double layer.

There are a variety of shrink-wrap types. Each shrink-wrap type is designed with special characteristics to meet specific packaging needs. For example, Sealed Air’s Cryovac® line consists of 9 different shrink films - each provide product-tailored performance characteristics such as:

• general-purpose
• abuse resistant/bundling
• soft shrink for soft goods and paper products
• high speed (75+ PPM)
• oxygen-barrier
• anti-fog

Equipments Used to Seal up Logistical Packaging

Heavy Duty Staple Guns

Till now, this is still traditionally used to seal up wooden crates that may contain fragile equipment.



In addition, safety labels/instructions & product charateristics that are pasted on the side of the wooden crates will enable the personnel handling the product furing exchanging of merchandise during transit (sea, air, road).

Tape Dispenser for Paper tape with glue

This is not commonly used to seal up corrugated fibreboard boxes (carboxes). Instead of using the traditional way of sealing the package up with scotchtapes, this particular company decided to use the brown paper film to seal up.

The precaution taken here is to prevent any pilferages especially during export shipment as any damages done to the brown paper film will be easily detected & immediate actions can be taken.

Plastic Foam

Latest Trend for Stuffing

Speedy Packer Plastic Foam Cushioning













Self-Made Video on how the Speedy Packer System Works:





Foam-filled bags can be created in a variety of sizes to be used for void fill, cushinoning, blocking and bracing and molded cushions.

Benefits of Foam Packaging:

Saves You Money-
Economical foam cuts your packaging material costs without compromising product protection.

Speeds Up Your Packaging Process-
Foam expands in seconds to form protective cushions, significantly improving productivity.

Makes Packaging the products-
It's easy, economically and efficiently protects products of any size, shape and weight.

Versatile-
Whether your packaging requirement is precision cushioning, high-speed void fill or heavy-duty blocking and bracing, the system will meet your needs.

Protects Your Products-
Foam has unique cushioning properties that protect your products during shipping, warehousing and handling.

Saves You Warehouse Space -
Foam expands up to 200 times its liquid volume, when, where and as you need it, significantly reducing the costs of storage and handling. Two 55-gallon drums of liquid components when combined can create a trailer-truck load of packaging material.

Bubble Wrap

Tradiitonal Materials Used for Stuffing

Bubble Wrap Cushioning

Bubble Wrap with Outer Paper Cushioning

Refrigerated Pallet

In recent years where the biomedical industry is thriving, the use of refrigerated pallet greatly increase.Some reasons why refrigerated pallet are widely used are

(a)Vaccines, drugs, blood, plasma, organs and tissue must be held at constant temperatures to remain useful

(b)Temperature sensitive electronics and equipment must be delivered to global markets safely

(c)Flowers, fine art or other high-end perishables require temperature control to maintian their quality

With this pallets goods which are temperature sensitve can be send throughout the world as maintaining the temperature is no longer a barrier.
AcuTemp is one company which produces such pallet, the picture above is one of its productthe AcuTemp AX2100LG Temperature Management Cargo Unit.These are some of its features

-Precision control of temperature sensitive shipments (+/-2°C)
-User selectable temperature from +4°C to +25°C
-Extended hold times - over 100 hours on battery in refrigeration mode at +22°C ambient
-Multiple power sources for global operation
-Large payload capacity, accepts standard GMA pallets in any orientation

Types of Pallets

Emerging Trend in Warehouses

Traditional pallets
made out of wood

Chipboard pallets/
Particle board pallets/
Press-wood Export Pallets

Made up of recycled materials

Latest Trend: Plastic Pallets

Barcode VS Radio Frequency Identification (RFID)

In today's technology, more and more companies are using RFID technology for their products packaging.


RFID Reader / Info. needed for Put Away

RFID Tag / Scanning the Product (Hand-held Scanner)










Radio Frequency Identification (RFID) is a data collection technology similar to barcodes, but instead of scanning a barcode it uses radio frequency communication to collect data from RFID tags.

Both RFID and barcoding can

• reduce receiving operations time





• reduce data collection labour





• improves data collection accuracy

• integrates data collected with other areas

However, i feel that companies might want to consider implementing RFID instead of barcoding if a choice has to be made between these 2 because RFID does not need line of sight there fore it has a longer reading distance as compare to barcodes which require line of sight and therefore the barcode has to be near the scanner in order to read.

In addition, RFID can read many products one time at less than a second but barcodes can only read one each time and a few seconds taken to read one barcode which would be more time consuming as compared.

However, barcodes also has an advantage which will be the lower cost of implentation as compare to RFID.

This link has a table that has the comparison between the 2 technologies.
http://www.inlogic.com/rfid/rfid_vs_barcode.aspx