Customer Overview
The customer was operating using a wrapping program utilizing a film that was originally specified by the equipment manufacturer during the program’s development phase.
The Challenge
The customer faced the task of finding
a new film to meet their application
performance needs from within IPG’s
existing offerings. The goal was to reduce cost by providing an alternative material that could be used across multiple locations and changes required for the equipment.
Results/Benefits
The first machines load retention went from 12.7 lbs. up to 15.0 lbs, a significant increase with a more secure pallet. Consumption was reduced by 51 rolls annually as a result of using the thinner gauge G7 ultra high performance film, allowing a cost savings of 14.2%. Additionally, reduced use of plastic from the thinner gauge also achieved a carbon emission reduction of 4,130 lbs annually.
The second machine provided even larger improvements due to the higher stretch rate and additional wrapping. Load Retention on these heavier products went from 18.3lbs. up to 22.6lbs. providing a much more stable pallet for shipping. This reduced consumption by 102 rolls annually. 8,299lbs of Carbon emission reduction is achieved annually, along with an estimated cost savings of 22.4%.
IPG is owned by Clearlake Capital Group, a certified minority-owned business enterprise (MBE).
Proposed Solutions
To evaluate a replacement film, two machines with slightly different setups were utilized. Considering the high pre-stretch and load retention requirements of the application, IPG’s newly developed G7 Ultra High Performance film, in a thinner gauge than originally specified, was used. Machine 1, running at 270-280% on mixed carton types, employed IPG’s G7 Ultra High Performance machine film in 45 gauge without making any adjustments to the equipment. Similarly, Machine 2, operating at
290% on mixed cartons with additional wraps at the top and bottom for securing heavier loads, also used IPG’s G7 Ultra High Performance machine film in 45 gauge without any equipment
modifications.
Conclusion
IPG was able to provide a direct replacement film that does not require equipment or setup modification. This customer saw both a performance gain through increased load retention and lowered their cost-per-pallet by utilizing our film in a reduce gauge thickness. They switched to Ultra High Performance Film G7 45 gauge in 10 different locations, and they will be adding additional locations in the future.